Systems for the high-speed application of paper-based end closures on composite containers

ABSTRACT

A system for assembling a container and closure comprising an expanding collet which has a plurality of pivoting collet segments, each configured to simultaneously pivot radially outward about a pivot point and comprising. The collet comprises a lip that is engagable with the rim of the open end of the container and an angled tip positioned radially inward from the lip and shaped to press a countersink portion of the closure against an interior wall of the container as the collet segments pivot radially outward. As the container and the chuck are brought together, the rim engages with the lips of the collet segments and causes the angled tips of the collet segments to pivot outward toward the interior wall of the container, thereby pushing the countersink portion of the closure against the interior wall of the container.

This application claims priority to U.S. Provisional Application No.63/125,013, filed on Dec. 14, 2020, and U.S. Provisional Application No.63/030,959, filed on May 28, 2020, both are incorporated by referenceherein in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to systems and methods for the high-speedapplication of paper-based end closures on composite containers.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates generally to containers and methods ofsealing such containers. Cylindrical paper-based or composite containersare often used for snack foods and similar products. Such containersoften have a membrane sealed to a top rim of the container, an overcapor end cap covering the membrane, and a metal closure seamed onto abottom rim of the container. Typically, the membrane is first sealed tothe top rim and the end cap is then applied to the container. Thecontainer is then filled with the products through the open bottom endof the container and the metal closure is then seamed onto the bottomrim of the container. The container may be flushed or evacuated duringthe bottom seaming process in order to preserve the stored products fora longer period of time.

The process described above, using metal bottom ends, may interfere withthe recyclability of certain containers, as seaming the metal closure tothe bottom of the container makes it very difficult to separate themetal closure from the container itself. Without the ability to separatethe paper-based body of the container from the metal bottom, thecontainer assembly, depending on its configuration, may be unable toenter either the paper or metal recycling stream. This may result inunnecessary waste and negative environmental impacts. There exists aneed for recyclable containers in order to increase the sustainabilityof the end product.

One solution to the need for recyclability is to produce containers withpaper-based end closures rather than metal ends. However, the existingequipment for seaming metal ends to containers is built specifically formetal ends, and simply swapping out metal closures for paper-based endclosures is incompatible with the current metal end seaming process, aspaper-based end closures introduce unique challenges not present withmetal ends (e.g., flexibility of the closures, separating the closuresfrom a stack of closures, feeding the closures, folding the closures,fusing the non-metal closures).

Through ingenuity and hard work, the inventors have not only developedsystems and methods for applying paper-based end closures to containers,but have developed systems and methods that operate at high speeds(e.g., over 300 containers per minute). Additionally, in certainembodiments, certain aspects of the disclosed systems and methods may beused to retrofit existing metal end seamers (e.g., Angelus 60L), therebysaving on new equipment costs.

BRIEF SUMMARY OF THE DISCLOSURE

In some embodiments, an assembly module for assembling a container andclosure may be provided. The containers and/or closures may bepaper-based. The container may have an open end circumscribed by a rim.The assembly module may include a chuck, an expanding collet, and anactuator. The chuck may be configured for axial alignment with thecontainer, and the actuator may be configured to bring the container andthe chuck axially together. In some embodiments, the chuck may beconfigured to be axially stationary. The expanding collet may be engagedwith the chuck and include pivoting collet segments. The collet segmentsmay each be configured to simultaneously pivot radially outward about apivot point. The collet segments may include a lip and an angled tip.Each lip of the collet segments may be positioned around the expandingcollet to be engaged by the rim of the open end of the container. Theangled tip of each collet segment may be positioned radially inward fromthe lip and shaped to press a countersink portion of the closure againstan interior wall of the container as the collet segments pivot radiallyoutward. As the container and the chuck are brought axially together bythe actuator, the rim of the container may engage with the lips of thecollet segments and cause the angled tips of the collet segments topivot outward toward the interior wall of the container, thereby pushingthe closure into the open end of the container and pressing thecountersink portion of the closure between the angled tips of the colletsegments and the interior wall of the container. The pivot point of eachof the collet segments may be located where the expanding collet engageswith the chuck. As the collet segments pivot radially outward about thepivot point, the diameter of the expanding collet may increase. In someembodiments, the diameter of the expanding collet may increase by about5% of the total diameter of the expanding collet. When the diameter ofthe expanding collet has increased to the maximum diameter (e.g., in itsfully expanded state), an exterior diameter of the angled tips of thecollet segments may be substantially equivalent to an inner diameter ofthe container. The length of the angled tip may correlate to acountersink depth of the closure within the open end of the containerwhen assembled. The angled tip may have an end proximate the lip and onedistal and be angled such that the expanding collet has a diameter atthe angled tip proximate end which is greater than a diameter at theangled tip distal end. In some embodiments, the lip may comprise asubstantially horizontal surface configured to engage the rim of thecontainer. In some embodiments, the expanding collet may be formed froma non-metal material.

In some embodiments, the expanding collet may further include anexpandable retainer. The expandable retainer may be configured to urgethe collet segments to pivot radially inward. The rim of the open end ofthe container may have a hoop strength greater than the urging force ofthe retainer through a predetermined expansion.

In some embodiments, the assembly module may further include acompressible backstop positioned to resist the pivoting of the colletsegments after a predetermined pivot distance. The assembly module mayalso include a secondary backstop positioned to prevent the pivoting ofthe collet segments after a predetermined secondary pivot distance. Thepredetermined secondary pivot distance may occur before thepredetermined compression.

In some embodiments, the assembly module may further include an assemblyrod positioned concentrically within the chuck and the expanding collet.The assembly rod may be configured to move axially to push a centralportion of the closure into the open end of the container as thecontainer and the chuck are brought axially together. The assembly rodmay include a centering disc that contacts a center of the closure asthe closure is pushed into the open end of the container.

In some embodiments, the assembly module may further include aperipheral sleeve, surrounding the chuck and expanding collet. Theperipheral sleeve may be configured to fold a peripheral skirt of theclosure over the rim and around an exterior wall of the container. Theperipheral sleeve may have an inner diameter larger than an outerdiameter of the container. The peripheral sleeve may further include aninner brim with gripping surface texture configured to contact thefolded peripheral skirt of the closure. The peripheral sleeve may beformed from a non-metal material. The assembly module may furtherinclude an o-ring positioned between the chuck and the peripheralsleeve, wherein the peripheral sleeve is movable rotationally andlaterally along the o-ring relative to the chuck. The peripheral sleevemay be axially stationary.

In some embodiments, the assembly module may further include a roller.The roller may be configured to move laterally relative to the chuck andpush the peripheral sleeve against a portion of the folded peripheralskirt of the closure. The container may be configured to be rotatedaxially relative to the roller. The expanding collet may resist thepushing action of the roller. The peripheral sleeve may be configured toshift eccentrically relative to the chuck when pushed by the roller.

In some embodiments, the assembly module may further include a membranearranged around the lips and the angled tips of the expanding collet toprevent ingress of debris between the collet segments. The membrane maybe formed from silicone and/or rubber.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the present disclosure in general terms, referencewill now be made to the accompanying drawings, which are not necessarilydrawn to scale, and wherein:

FIG. 1 is a cross-sectional side perspective view of an examplecontainer (e.g., rigid composite can) and closure (e.g., paper-based endclosure), in accordance with some embodiments of the present disclosure;

FIG. 2A is a cross-sectional view of an example closure before applyingto a container, in accordance with some embodiments of the presentdisclosure;

FIG. 2B is a cross-sectional view of the closure of FIG. 2A after beingapplied to a container, in accordance with some embodiments of thepresent disclosure;

FIG. 2C is a cross-sectional view of a closure after being applied to acontainer in accordance with some embodiments of the present disclosure;

FIG. 2D is a cross-sectional view of a closure and container inaccordance with some embodiments of the present disclosure;

FIG. 3 is a bottom perspective image of an example container assemblyformed from the application of a closure to a container, in accordancewith some embodiments of the present disclosure;

FIG. 4 is a top plan view of a seaming system diagram including aconveyor for conveying containers through various modules (e.g., aseparate and feed module, an assembly module, a fusing module), inaccordance with some embodiments of the present disclosure;

FIG. 5 is a top-side view of an example assembly module and fusingmodule above a rotary turntable, configured to rotate and conveycontainers and closures through the modules within the seaming systemthereby producing container assemblies, in accordance with someembodiments of the present disclosure;

FIG. 6 is a top-side view of an example separate and feed module,configured to use vacuum cups mounted in a spindle arrangement to eachremove an individual closure from a stack of closures and transfer theindividual closure to a pocketed turret, which rotates to deposit theclosure atop an open end of a container, in accordance with someembodiments of the present disclosure;

FIG. 7 is a bottom-side view of an example assembly module comprising achuck and an expanding collet in its unexpanded state, in accordancewith some embodiments of the present disclosure;

FIG. 8 is a bottom-side view of the assembly module of FIG. 7 in itsfully expanded state, in accordance with some embodiments of the presentdisclosure;

FIG. 9 is a bottom plan view of the assembly module of FIGS. 7-8 in itsunexpanded state, wherein collet segments that together form theexpanding collet are unpivoted, in accordance with some embodiments ofthe present disclosure;

FIG. 10 is a cross-sectional side view of the assembly module of FIGS.7-9 in a partially expanded state, wherein a front stop portion of thecollet segments is just pivoted away from abutting a front stop of thechuck, in accordance with some embodiments of the present disclosure;

FIG. 11 is a cross-sectional side view of an example container andclosure engaged with the assembly module of FIGS. 7-10 in a partiallyexpanded state, caused by an upward force of a rim of the containeracting on the collet segments to pivot them away from the front stopportion toward a back stop portion of the chuck, in accordance with someembodiments of the present disclosure;

FIG. 12 is a cross-sectional top-side view of an example container andclosure engaged with an assembly module including a lateral-movingroller, a peripheral sleeve, a chuck, and an expanding collet in apartially expanded state, in which the container has pivoted colletsegments away from a front stop of the chuck to abut a compressible backstop, in accordance with some embodiments of the present disclosure;

FIG. 13 is a cross-sectional top-side view of the container, closure,and assembly module of FIG. 12 in its fully expanded state, in which thecontainer has pivoted the collet segments all the way such that a backstop portion of the collet segments abuts a hard back stop of the chuck,in accordance with some embodiments of the present disclosure;

FIG. 14 is a cross-sectional top-side view of the container, closure,and assembly module of FIGS. 12-13 in its fully expanded state with theroller moved laterally to shift the peripheral sleeve eccentricallyrelative to the chuck, and further including an example fusing module,in accordance with some embodiments of the present disclosure;

FIG. 15 shows a cross-sectional side view of an example container andclosure moving upward toward an assembly module including alateral-moving roller, a peripheral sleeve, a chuck, and an expandingcollet in its unexpanded state, in which collet segments abut a frontstop of the chuck, in accordance with some embodiments of the presentdisclosure;

FIG. 16 shows a cross-sectional side view of the container, closure, andassembly module of FIG. 15 in its fully expanded state, in which thecontainer has pivoted the collet segments away from the front stop toabut a back stop of the chuck, as the roller moves laterally toward thechuck, in accordance with some embodiments of the present disclosure;

FIG. 17 shows a cross-sectional side view of the container, closure, andassembly module of FIGS. 15-16 in its fully expanded state with aperipheral skirt of the closure pinched between the container and theperipheral sleeve, which has been shifted eccentrically relative to thechuck by the lateral movement of the roller, in accordance with someembodiments of the present disclosure;

FIG. 18 shows a cross-sectional bottom-side view of an example containerand closure under an assembly module including a peripheral sleeve, achuck, an expanding collet, and an expandable membrane surrounding theexpanding collet, in accordance with some embodiments of the presentdisclosure;

FIGS. 19-24 show cross-sectional side views of example containers andclosures within the assembly module along with example fusing modules,in accordance with some embodiments of the present disclosure;

FIGS. 25-35 show various example embodiments of the fusing module, inaccordance with some embodiments of the present disclosure;

FIG. 36 illustrates a top view of a peripheral sleeve in accordance withsome embodiments of the present disclosure;

FIG. 37 illustrates a perspective view of a peripheral sleeve inaccordance with some embodiments of the present disclosure;

FIGS. 38-41 illustrate cross-sectional views of a separate and feedmodule in accordance with some embodiments of the present disclosure;

FIGS. 42-43 illustrate cross-sectional views of the fusing module of theinvention, in accordance with some embodiments of the presentdisclosure;

FIG. 44 illustrates exemplary finished container and paper ends inaccordance with some embodiments of the present disclosure;

FIG. 45 illustrates an exemplary induction coil in accordance with someembodiments of the present disclosure;

FIG. 46 illustrates an exemplary concentrator used in connection with aninduction coil in accordance with some embodiments of the presentdisclosure;

FIGS. 47A-47D illustrate various angles of an exemplary concentrator foruse in accordance with some embodiments of the present disclosure;

FIG. 48 illustrates a three-dimensional printed example of the assemblymodule in accordance with some embodiments of the present disclosure;

FIG. 49 illustrates an embodiment of the separate and feed module,assembly module, and sealing module, in accordance with some embodimentsof the present disclosure;

FIG. 50 illustrates an embodiment of a cross-sectional top-side view ofthe container, closure, and assembly module in its fully expanded state;and

FIG. 51 illustrates an embodiment of a cross-sectional top-side view ofthe container, closure, and assembly module in its fully expanded state.

DETAILED DESCRIPTION OF THE DISCLOSURE

While this present disclosure may be embodied in many forms, there isshown in the drawings and will herein be described in detail one or moreembodiments, with the understanding that this disclosure is to beconsidered an exemplification of the principles of the presentdisclosure and is not intended to limit the disclosure to theillustrated embodiments.

Rigid Composite Containers

Rigid, paper-based, composite containers are used to package variousproducts such as snacks and other food items. These containers oftencomprise a rigid cylindrical or shaped body usually manufactured withthe top and bottom ends open. The composite containers may compriserigid cans made from wound sheet material, such as cardboard and/orpaperboard. In an embodiment, the containers may be spirally wound.While the bottom end closure is usually permanently affixed to thecontainer, the top end closure is often designed to be easily removed bythe consumer (i.e., a removable overcap and/or a peelable membrane).

FIG. 1 is a cross-sectional side perspective view of an examplecontainer 202. The container 202, also shown in FIGS. 3 and 11-14 , maycomprise a rigid cylindrical body having a sidewall 206 terminating in arim 205 at an open end 203. In this embodiment, the open end 203 maycomprise a bottom end of the container 202. In some embodiments, theopen end 203 may be sealed with a closure 204 (e.g., paper-based endclosure). In some embodiments, the container 202 may additionally have asecond open end (e.g., the top end), opposite the open end 203, whichmay be sealed with a flexible membrane or other closure.

The open end 203 of the container 202 may be circumscribed by a rim 205formed by the terminating edge of the sidewall 206 that forms the bodyof the container 202. The sidewall 206 may include an interior surface207 facing the inside of the container 202 and an exterior surface 208facing the outside of the container 202. The interior surface 207 may bethe product-facing side of the sidewall 206 of the container 202. Insome embodiments, the product(s) may be food products, and the interiorsurface 207 may include a food-safe layer and/or coating to help protectthe integrity of the food product(s) to be contained within thecontainer 202. The exterior surface 208 may include printing or otherapplied graphics for labeling and/or advertising the product(s) to becontained within the container 202.

In some embodiments, the rigid sidewall 206 of the container 202 maycomprise multiple layers of paper, metal foil, and/or sealant. Forexample, moving from the exterior surface 208 inward, the sidewall 206may comprise an outer ply of paper (e.g., white) coated with a sealant,two sandwiched plies of paper (e.g., brown cardboard or paperboard), andan inner lining of metal foil (e.g., about 0.0003 in. thick Aluminum)coated with a sealant. The metal foil lining and sealant layers mayadvantageously aid in the induction heating process—to seal the closure204 to the container 202. Any combination of container layers (paper,metal, and/or sealant) may be utilized in the invention.

In some embodiments, the interior surface 207 and/or exterior surface208 may include a layer of sealant at the open end 203 of the container202 that may melt and seal the assembled closure 204 to the container202. In some embodiments, the sealant layer may be disposed throughoutthe interior surface 207 and/or exterior surface 208 of the container202 or may be disposed only along the edge(s) of the open end 203 of thecontainer 202. In other embodiments, however, no separate sealantmaterial is used.

Paper-Based End Closures

In some embodiments, the closure 204 of the present disclosure may be apaper-based end closure. In an embodiment, the closure 204 may be agenerally flat circle or disc, sized to overlay the circumference of theopen end 203 of the container 202. In an embodiment, the closure 204 maybe a generally flat circle or disc, sized to be inserted into, in arecessed manner, the circumference of the open end 203 of the container202. In another embodiment, the closure 204 may be pre-stamped, as shownin FIG. 1 . In either case, the rotational/circumferential orientationof the closure 204 relative to the container 202 may be ignored wherethe container 202 and closure 204 are uniform throughout all angles ofrotation. Other shapes (e.g., rectangular, polygon with extended side)are possible, however.

As discussed herein, the top and/or bottom sides 204 a, 204 b of theclosure 204 will be referred to in the context of the orientation of theclosure 204 when applied to the open end 203 of the container 202. Here,as shown in FIG. 1 , the container 202 is oriented with respect to theclosure 204 with the rim 205 of the open end 203 of the container 202facing upward so as to first contact the bottom/lower/under/inner side204 b of the closure 204 that faces downward with the top/upper side 204a of the closure 204 facing upward. In embodiments where the open end203 of the container 202 is the bottom of the container 202, the topside 204 a of the closure 204 would thus be facing downward when thecontainer assembly 406 (shown in FIG. 3 ) is oriented upright. It shouldbe understood that other orientations not depicted in the presentdisclosure are possible for applying the closure 204 to the container202, but the upper/top side 204 a of the closure 204 may be that whichfaces outside when assembled as part of the end-product containerassembly 406, and the bottom/lower/under side 204 b is that which facesthe product(s) inside the container 202 when assembled as part of theend-product container assembly 406.

In some embodiments, the closure 204 may be pre-stamped and/orpre-formed with specific structural features (see FIG. 1 ). The stampingand/or pressing process may include feeding flat closure material into adie press (e.g., stamping press) and compressing the material betweenopposing dies.

While the closure 204 may be made primarily of paper and otherfiber-based material, it may also contain non-fiber barrier layers madefrom metal and/or plastic. In some embodiments, the closure material maycomprise multiple layers of paper, metal, and/or sealant. For example,the closure may comprise two plies of paper (e.g., white) on the topside and/or a metal foil layer (e.g., about 0.0003 in. thick Aluminum)coated with a sealant on the bottom side 204 b. The metal foil layercoated with sealant may advantageously be used with induction heating toseal the closure 204 to the container 202. In some embodiments, thesealant may be applied to the bottom side 204 b of the closure 204 onlyaround the outer periphery where the closure 204 is configured tocontact the container 202. In other embodiments, the sealant may beapplied to the entire bottom side 204 b of the closure 204.

FIGS. 2A-2C show cross-sectional views of an embodiment of thepre-formed closure 204, both prior to and after assembly with thecontainer 202. Before assembly, the pre-formed closure 204 may have asubstantially flat central portion 240 in its center, an annular chuckwall 242 radially surrounding and extending in an angled vertical mannerfrom the central portion 240, and (optionally) a peripheral skirt 209extending radially outward from the chuck wall 242. The peripheral skirt209 may also be disposed in an angled vertical manner. As noted above,in other embodiments, the entirety of closure 204, prior to insertioninto a container 202, may be substantially flat or flat and disc-shaped.

In some embodiments, the central portion 240 of the closure 204 may besubstantially flat and horizontal, but include one or more convexprotrusions 240 a, 240 b rising from its top side. The one or moreconvex protrusions 240 a, 240 b may advantageously reserve additionalmaterial and/or surface area of the closure 204 within the centralportion 240 that may be stretched as the closure 204 is expanded withinthe open end 203 of the container 202 (e.g., when the chuck wall 242 ispressed against the interior surface 207 of the sidewall 206 of thecontainer 202). In some embodiments, the one or more convex protrusions240 a, 240 b may additionally provide flexibility within the closure 204such that any damage and/or distortion to the container assembly 406 andits seal (e.g., hermetic) due to the changing pressure differentialbetween the outside and the inside of the sealed container assembly 406may be minimized. In this way, the convex protrusions 240 a, 240 bformed into the closure 204 may help ensure the integrity of theproduct(s) contained within. In other embodiments, the central portion240 of the closure 204 may include one or more concave protrusions or acombination of concave and convex protrusions.

As shown in FIG. 2A, in some embodiments, the central portion 240 mayinclude a dome 240 a at the center of the closure 204 atop a plateau 240b surrounding it. In an embodiment, the radially outward edge of theplateau 240 b may circumscribe the plateau 240 b and form an obtuseangle with a substantially horizontal flat annular ring 240 c that formsthe lowest portion of the closure 204 on its top side 204 a (and thehighest ledge of the closure 204 on its bottom side 204 b). Saidalternatively, the annular ring 240 c may be the furthest point from theouter edge of the skirt 209 prior to application of the closure 204 tothe container 202. In certain embodiments, the annular ring 240 c may begenerally U-shaped.

Further radially outward from and adjacent to the annular ring 240 c, achuck wall 242 may be pre-formed and/or stamped into the closure 204.The chuck wall 242 may form an obtuse angle with the annular ring 240 c.In this way, the diameter of the lower portion of the chuck wall 242adjacent the annular ring 240 c may be less than the diameter of itsupper portion adjacent the peripheral skirt 209.

The chuck wall 242 may be configured to be pressed against the interiorsurface 207 of the sidewall 206 of the container 202 when inserted intothe open end 203 of a container 202, thus forming a countersink portion244 (shown in FIGS. 2B and 2C, which represent cross-sectional views ofvarious closures 204 after being assembled with a container). Thelength/height of the chuck wall 242 may correlate to a predeterminedcountersink depth 246 of the countersink portion 244 of the closure 204within the open end 203 of the container 202 when assembled.

In some embodiments, further radially outward from and adjacent to thechuck wall 242, the peripheral skirt 209 may extend in a generallyhorizontal direction. The peripheral skirt 209 may be configured to foldover the rim 205 of the sidewall 206 of the container 202 at its openend 203. In some embodiments, the length of the peripheral skirt 209 maybe sufficiently long such that the peripheral skirt 209 extends farenough beyond the rim 205 of the container 202 to be folded around therim 205 to contact the exterior surface 208 of the sidewall 206 of thecontainer 202. In some embodiments, the peripheral skirt 209 may befurther pressed and sealed against the exterior surface 208 of thesidewall 206 of the container 202. In this way, the closure 204 mayadvantageously form two seals with the container 202 (e.g., one with theinterior surface 207 and one with the exterior surface 208). Providingdouble seals between the container 202 and the closure 204 may aid inmaintaining the hermetic seal. In some embodiments, the closure 204 mayform a single continuous seal with the container 202 through thecountersink portion 244, over the rim 205, and through the peripheralskirt 209.

In other embodiments, shown in FIGS. 2C-2D, the closure 204 may beconfigured such that the peripheral skirt 209 is recessed within orpositioned inside the container 202 body. In this embodiment, theperipheral skirt 209 may not fold around the rim 205 to contact theexterior surface 208 of the sidewall 206 of the container. In anembodiment, the top surface 204 a of the closure 204 may be spaced awayfrom (e.g., recessed within) the bottom peripheral edge 205 of thecontainer 202 body. The closure 204 may be recessed into the containerbody 202 at a predetermined recessed distance “D_(r)”. The recesseddistance “D_(r)” may be measured from the bottom peripheral edge or rim205 of the container body 202 to the surface 204 a of the bottom closure204. In some embodiments, the recessed distance “D_(r)” may be within arange of about 0.2-2 cm (about 0.08-1.2 in.). For example, the recesseddistance “D_(r)” may be about 0.7 cm (about 0.275 in.). The recesseddistance “D_(r)” may be configured to minimize any protrusion of thesurface 204 a of the bottom closure 204 past the bottom peripheral edgeor rim 205 of the container body 202 when the container assembly isexposed to higher pressure differentials between the container interiorand external environment. For example, the depth of the recesseddistance “D_(r)” of the bottom closure 204 may ensure that bottomclosure 204 will not over inflate past the bottom peripheral edge or rim205 of the container body 202 at pressure differentials exceeding about10 inHg (˜34 kPa). In this way, the recessed distance “D_(r)” combinedwith the integrity of the hermetic seal may help prevent distension ofthe closure beyond peripheral edge or rim 205 of the container body 202,rocking of the container body 202 when it is positioned upright, and/orother issues with the bottom closure 204.

The inventors have surprisingly discovered that the hermeticity of thebottom closure against the interior surface 207 of the container body202, in this embodiment, can be maintained using a recessed closure 204that is affixed to only the interior surface 207 of the container body202. As will be disclosed herein, the closure 204 may be pushed into thecontainer body 202 any distance that would be practical in the art. Insome embodiments, the closure 204 becomes a recessed bottom. In someembodiments, the peripheral edge of the closure 204 is flush with theedge or rim 205 of the sidewall of the container body 202 (see FIG. 2D).In other embodiments, the peripheral edge of the closure 204 is disposedinward, in relation to the peripheral edge or rim 205 of the sidewall206 of the container body 202.

The closure 204 may be recessed inside the container body 202 to form afirst deformed surface 204 c of the closure 204 is spaced away from(e.g. recessed within) the bottom peripheral edge 205 of the containerbody 202. The first deformed surface 204 c may comprise a centralportion of the closure 204. In an embodiment, the first deformed surface204 c may be flat, substantially flat, horizontal or substantiallyhorizontal. During insertion of the closure 204 into the container body202, as will be explained, in some embodiments, the peripheral skirt 209of the closure 204 may be bent at a right angle or a near-right angle,shown as the second deformed surface 204 d in FIG. 2D. The resultingsecond deformed surface 204 d (previously the peripheral skirt 209) ofthe closure 204 may be disposed vertically or nearly vertically,adjacent the interior surface 207 of the container body 202, at the openbottom end 203.

System

In some embodiments, the invention comprises a system for applying andsealing a closure (e.g., paper-based end closure) to a container body(e.g., composite can). In an embodiment, the system of the presentdisclosure may comprise at least a separate and feed module 100, anassemble and press module 200, and a fusing module 300. The variousmodules may be utilized separately and/or as part of an overall system.

The system may include a conveyor for conveying the container bodiesthrough the modules. The conveyor may also include different sectionsfor moving the container bodies in different manners through the system.In some embodiments, the conveyor may include a rotary turntable 32 thatconveys the container bodies in a rotational path through one or moremodules.

In some embodiments, as shown in FIG. 4 , the conveyor may include aninfeed conveyor 44 that conveys the container bodies 202 to the modules.The infeed conveyor 44 may comprise a feed screw 46 or any othersuitable type of mechanism for conveying the container bodies to thesystem. The feed screw 46 may feed the container bodies to a pocketedturret device 52. The turret device 52 may convey the container bodiesthrough the separate and feed module 100.

Next, the container bodies may be fed from the turret 52 to a transferturret 58. The transfer turret 58 may advance the container bodies oneat a time to the assembly module 200.

In some embodiments, the rotary turntable 32 may include chambers 34.The rotary turntable 32 may support a plurality of chambers spaced aboutits circumference. Each chamber essentially comprises a cylindrical tubeinto which a container body with a closure resting thereon may beloaded. The chamber's bottom may comprise a lifting plate.

In some embodiments, as shown in FIG. 5 , one or more assembly modules200 and/or fusing modules 300 may be mounted above the turntable 32. Theturntable may include lifting plates. Each lifting plate may bevertically movable relative to the assembly module 200. A cam may bemounted beneath the turntable 32 and may engage lifters attached to thelifting plates. As the turntable 32 is rotated about its axis, thelifter may be moved vertically according to the cam profile to cause thelifting plate to rise and fall, thereby lifting and lowering thecontainer body, in order to perform the various operations involved inthe assemble and press module 200.

Separate and Feed

In some embodiments, the present disclosure includes novel systems andmethods for separating and feeding individual closures (e.g.,paper-based end closures) from a closure supply onto individualcontainers (e.g., rigid cylindrical composite cans) (see FIG. 6 ). Insome embodiments, as the containers (e.g., composite cans) are conveyedthrough the system, the closures 204 (e.g., paper-based end closures)may be placed onto open ends 203 of the containers 202. Prior to placingclosures 204 onto containers 202, the closures 204 may be separated froma stack of closures 204 and fed individually onto each container 202.Thus, the separate and feed module 100 will be described.

In some embodiments, the separate and feed module 100 may be capable ofseparating a single closure 204 from a stack of closures 204 and feedingthe closure 204 into an outfeed screw assembly at a rate of at least 200closures per minute. In other embodiments, the separate and feed module100 may be capable of separating a single closure 204 from a stack ofclosures 204 and feeding the closure 204 into an outfeed screw assemblyat a rate of at least 300 closures per minute. In some embodiments, theseparate and feed module 100 may be capable of separating a singleclosure 204 from a stack of closures 204 and feeding the closure 204into an outfeed screw assembly at a rate of at least 400 closures perminute. In still another embodiment, the separate and feed module 100may be capable of separating a single closure 204 from a stack ofclosures 204 and feeding the closure 204 into an outfeed screw assemblyat a rate of at least 450 closures per minute. In an embodiment, theseparate and feed module 100 may be considered a high-speed separate andfeed system.

Referring to FIGS. 38-41 , generally speaking, the closures (e.g.,stamped paper ends) 204 may be provided in a stacked configuration. Forexample, the closures 204 may be provided to the system via agravity-fed closure infeed track 105. The infeed track 105 may contain aplurality of stacked closures 204. The infeed track 105 may generallyhave a size, shape, and configuration which is similar to or the same asthe closures 204. For example, if the closures 204 are generallydisc-shaped, the infeed track 105 may be generally cylindrical and mayenclose a stack of closures 204 within the cylindrical portion. In anembodiment, the infeed track 105 may have an accordion configuration,such that it may bend, rotate, or twist as needed for the system. In anembodiment, the infeed track 105 may be disposed such that the closures204 are stacked vertically or substantially vertically, with the opening122 of the infeed track 105, which then deposits the closures 204 facingdownwardly or generally downwardly. Alternatively, the infeed track 105may be disposed horizontally or substantially horizontally. Anyconfiguration may be utilized.

The closures 204 may be disposed in the infeed track 105, in anembodiment, with their non-product-facing surface 116 facing the opening122 in the separate and feed module 100. In an embodiment, the infeedtrack may comprise clips 120 on its open end 122 which hold or securethe closures 204 within the track 105 until removal of each closure 204.The clips 120 may take any form or shape which retains the closures 204in place within the track 105 but allows deformation of the closures 204sufficient to allow the closures 204 to be removed from the infeed trackat the appropriate time. In an embodiment, the clips 120 are disposedpartially into the circumference of the open end 122 of the infeed track105. Alternatively, the open end 122 may have integral features whichretain the closures 204 within the infeed track 105 until they areremoved by the system.

The separate and feed module 100 may remove one closure 204 at a timefrom the stack of closures and deliver it to a servo-driven screw, screwconveyor, or other device known in the art, in an embodiment. The screwconveyors can be driven by any known mechanism, such as a belt, gear,chain or other system. In an embodiment, the screw may rotatecontinuously. In other embodiments, the screw may stop and start,wherein the screw stops are correlated to the placement of a closure 204within the screw. For example, the screw may rotate at a continuousspeed and the stop when the screw is positioned below the displacementlocation for the closure 204. In still other embodiments, the screw mayrotate at a continuous speed and slow when the screw is positioned belowthe displacement location for the closure 204. In an embodiment, thescrew may be timed to the separate and feed module 100. It should benoted that in FIGS. 40 and 41 , multiple closures 204 are shownvertically aligned below the displacement location for the system 100.In an embodiment, the closures 204 would be conveyed horizontally priorto another closure 204 being placed into the screw. Thus, in anembodiment, the closures 204 would not be simultaneously verticallyaligned.

In some embodiments, the separate and feed module 100 may comprise aservo-driven four (4) head 113 transfer dial 111, each with a vacuum cup114 mounted in a spindle arrangement. That being said, any number ofheads is contemplated herein. In an embodiment, the system comprises atwo (2) axis servo system.

Referring to FIG. 40 , the removal of a closure 204 from the infeedtrack 105 is shown. In an embodiment, a closure 204 is removed from theinfeed track 105 by the vacuum cup 114. In an embodiment, the vacuum cup114 is mounted on the head 113 and rotates about the dial 111 in aclockwise or counterclockwise motion, about an axis of rotation shown asX₁, in the center of the transfer dial 111. Likewise, the vacuum cup 114may rotate about the head 113 in a clockwise or counterclockwise motion,about an axis of rotation shown as X₂, in the post supporting the head113. Thus, it can be understood that the vacuum cups 114 cansimultaneously rotate about the axes X₁ and X₂. In an embodiment, therotation about axes X₁ and X₂ is in the same direction (i.e. clockwiseor counterclockwise).

As a vacuum cup 114 approaches the open end 122 of the infeed track 105,the vacuum cup 114 is rotated to meet the open end 122 of the infeedtrack 105. The vacuum cup 114 is pressed into the first closure 204 inthe open end 122 of the infeed track 105. Using suction formed basedupon the shape of the vacuum cup 114 and/or using forced vacuumed air,sucked inward through a line 110, the closure is temporarily affixed tothe vacuum cup 114. As the dial 111 and/or head 113 rotates, the vacuumcup 114 is moved away from the infeed track 105. Due to thesuction/vacuum forces, the closure 204 is retained on the vacuum cup 114and moves with the vacuum cup 114 (see FIG. 40 ). The closure 204 maydeform slightly to pass the clips 120 as it is removed from the infeedtrack 105.

In some embodiments, the separate and feed module 100 may comprise avacuum manifold with a blow-off port 112. In this embodiment, the vacuumfunction may retain the closure 204 on the vacuum cup 114 duringtransfer and the blow-off port may exert a blast of pressurized air toremove the closure 204 from the vacuum cup 114 upon delivery to thescrew 125. Thus, in this embodiment, the vacuum function may beactivated until the blow-off function is triggered. In an embodiment,the blow-off port may use house air or a reservoir.

In some embodiments, the vacuum cup engages the exterior side 204 a(i.e. non-product-facing surface 116) of the closure. In otherembodiments, the vacuum cup engages the interior side 204 b (i.e.product-facing surface) of the closure. In a particular embodiment, thevacuum cup 114 contacts only the surface 116 of the closure 204 whichwill eventually be outwardly-facing on the container. That is, thevacuum cup 114 may not, in an embodiment, contact the food- orproduct-facing side 118 of the closure 204. This may provide for a moresanitary application process, particularly for containers housing food,beverages, pharmaceuticals, or other similar products.

In some embodiments, the rotary motion of each head 113 may be geared tothe motion of the transfer dial via a timing belt. In some embodiments,the system may feed the closures 204 into one or more outfeed screwassemblies 124. In an embodiment, the system 101 drops the closures 204vertically into a screw. The outfeed screw assembly 124 may transfer theclosure 204 to a rotating dial. In an embodiment, the rotating dial maybe continuously rotating about the system 100. The rotating dial maythen convey the closure to a container 202, optionally in connectionwith a body turret. In some embodiments, the outfeed screw comprises oneor more (in some cases, three (3)) feed screws, which may also beservo-driven and may be geared together and to the transfer dial. Inother embodiments, the vacuum cup 114 rotates the closure 204 to aposition adjacent a container 202 or directly onto a container 202. Insome embodiments, the closure 204 may be positioned above a container202 by the system 100.

As shown in FIGS. 4 and 6 , the separate and feed module 100 may beassociated with a pocketed turret 54. In this embodiment, the turretdevice 52 of the conveyor may convey the containers to the pocketedturret 54. The separate and feed module 100 may be configured to feedand deposit closures 204 into each pocket of the turret 54.

In any embodiment, the closure 204 may then be loosely placed on thecontainer 202, optionally within a vacuum chamber. The container 202 andclosure 204 may then be conveyed to the assemble and press module, in anembodiment.

Assemble and Press

In some embodiments, the system 100 may include an assembly module 200for assembling containers 202 (e.g., composite cans) and closures 204(e.g., paper-based end closures). The assembly process for thecontainers 202 and closures 204 may include applying a closure 204 to anopen end 203 of a container 202 and folding and pressing specificportions of the closure 204 to seal (e.g., hermetically) the container202 closed.

As shown in FIGS. 7-18 , the assembly module 200 may include a chuck 220engaged with an expanding collet 210. Generally speaking, the chuck 220and expanding collet 210 of the assembly module 200 may be configured toprovide a controlled and repeatable pressing and folding action on theclosures 204 during assembly with the containers 202. In this way, thechuck 220 and expanding collet 210 may insert, press, and fold theclosure 204 into, against, and around the open end 203 of the container202. More particularly, the expanding collet 210 may be configured to bepartially inserted into the open end of the container 202 (adjacentclosure 204) and then expanded outwardly to press the closure 204against the interior surface 207 of the container 202. The closure 204may also simultaneously or sequentially, in various embodiments, bepressed over the rim 205 of the sidewall 206 of the container 202 andagainst the exterior surface 208 of the container 202 (e.g., by aperipheral sleeve 230, as discussed herein).

Turning now to specific embodiments, in some embodiments, the chuck 220may be configured such that the chuck 220 does not move verticallyrelative to the container 202 (i.e., is vertically stationary). That is,the chuck 220 does not move vertically upward and downward. For clarity,while the chuck 220 may be vertically stationary, the chuck 220 maycontinuously spin about its axis and/or revolve around the turret centerof the machine.

In such an embodiment, the container 202 is raised upward to meet thechuck 220 and collet 210. In such embodiments, the system 100 mayinclude lifting plates on which the containers 202 are elevated tocontact the chuck 220 and expanding collet 210, pneumatically orotherwise. The lifting plates may be configured to axially align the rim205 of the container 202 with certain portions of the expanding collet210 before raising the container 202 to engage the container rim 205with the closure 204, chuck 220, and/or expanding collet 210. In otherembodiments, a bell guide may drive the closure 204, container 202, andchuck 220 into alignment.

Additionally, the lifting plates may be configured to rotate thecontainer 202 (e.g., revolving about a central longitudinal axis of thecontainer). In some embodiments, the rotational speed of the container202 may be at least 1000 rotations per minute (RPM). In otherembodiments, the rotational speed of the container 202 may be at least2000 RPM. In some embodiments, the rotational speed of the container 202may be within the range of about 1000 RPM to about 2000 RPM.

Additionally, the lifting plates may be configured to translate thecontainer 202 (e.g., horizontally along a path). In some embodiments,the translational path may be circular or semi-circular. In someembodiments, the translational speed of the container 202 may be atleast 50 RPM. In other embodiments, the translational speed of thecontainer 202 may be at least 100 RPM. In some embodiments, thetranslational speed of the container 202 may be within the range ofabout 50 RPM to about 100 RPM.

As will be understood, the rotation and translation of the container 202may aid in the fusing of the closure 204 to the container 202 and/or inthe pressing of the closure 204 to the exterior surface 208 of thesidewall 206 of the container 202. In an embodiment, the translationaland rotational movement of the containers 202 at such speeds allows forcommercial application of closures 204 to containers 202 at rates of atleast 400 or 420 containers per minute (“CPM”). In another embodiment,the translational and rotational movement of the containers 202 at suchspeeds allows for commercial application of closures 204 to containers202 at rates of at least 500 CPM. In still another embodiment, thetranslational and rotational movement of the containers 202 at suchspeeds allows for commercial application of closures 204 to containers202 at rates of at least 600 CPM.

One or more additional parts of the assembly module 200 may beconfigured to rotate in sync with the lifting plate and/or container202. For example, the chuck 220 and/or the expanding collet 210 mayrotate at substantially the same rotational speed as the lifting plateand container 202 during assembly of the container 202 with a closure204 in order to minimize frictional forces due to relative movementbetween the container 202, the chuck 220, expanding collet 210, and/orother parts of the assembly module 200.

Additionally or alternatively, the system 100 may lower the chuck 220and expanding collet 210 onto the rim 205 of the open end 203 of thecontainer 202 to apply the closure 204. In either case, the pressingforce of the container 202 into the collet 210 or the collet 210 intothe rim 205 of the container 202 may be between about ten (10) andthirty (30) pounds of pressure. In a particularly, embodiment, thepressing force may be about twenty (20) pounds.

Chuck

As noted above, the assembly module 200 may include a chuck 220 engagedwith an expanding collet 210. In an embodiment, the chuck 220 may begenerally cylindrical with indentations formed and/or cut into itscircumferential surface to form alcoves for engaging with the expandingcollet 210. In an embodiment, the chuck 220 may comprise an upperportion 220 a and a lower portion 220 b. The diameter of the upperportion 220 a may be greater than the diameter of the lower portion 220b, in an embodiment. The lower portion 220 b of the chuck 220, in anembodiment, may be the portion that is engaged with the collet 210. Inan embodiment, the chuck 220 may additionally comprise a neck portion220 c disposed above the upper portion 220 a. The neck portion 220 c mayhave a smaller diameter than the upper portion 220 a and/or lowerportion 220 b.

In some embodiments, the center of the chuck 220 may comprise a centralhollow portion (e.g., a through hole or bore) with internal threadingfor mounting the chuck 220 onto cooperating threaded parts of the system100.

Expanding Collet

The expanding collet 210 may surround the generally cylindrical lowerportion 220 b of the chuck 220. In an embodiment, the expanding collet210 may also be generally cylindrical and may comprise a plurality ofindividual collet segments 212. Portions of the expanding collet 210 maybe inserted into indentations and/or alcoves of the lower portion 220 bof the chuck 220, creating engagement between the expanding collet 210and the chuck 220.

In some embodiments, the expanding collet 210 may be configured to pivotaxially upward and/or radially outward as the rim 205 of the open end203 of the container 202 moves axially toward the chuck 220 and engagesthe expanding collet 210.

The expanding collet 210 may have different states of expansion. Forexample, as shown in FIG. 7 , the expanding collet 210 may have aresting or unexpanded state in which the collet segments 212 areinitially unpivoted. In the unexpanded state, the expanding collet 210may have the smallest diameter and/or circumference compared to otherstates of expansion. As shown in FIG. 8 , the expanding collet 210 mayhave a fully expanded state in which the collet segments 212 are unableto pivot any further. In the fully expanded state, the expanding collet210 may have the largest diameter and/or circumference compared to otherstates of expansion.

As the collet segments 212 pivot radially outward about the pivot point213, the overall diameter and/or circumference of the expanding collet210 may increase. In some embodiments, the diameter of the expandingcollet 210 may increase by approximately 5% of the total diameter (e.g.,widest diameter) of the expanding collet 210. In an embodiment, thediameter of the expanding collet 210 may increase by about 5% at maximumrotation of the collets (i.e., when the collet is at the expanded statewith the widest diameter).

In some embodiments, the expanding collet 210 may operate similar to aHoberman sphere, expanding to its desired final shape with a singleactuation. In some embodiments, the expanding collet 210 may beconfigured such that the actuation from the unexpanded state to thefully expanded state occurs solely due to the force of the container 202acting on the collet segments 212 of the expanding collet 210. In thisway, the assembly module 200 may not require a separate driver foractuating or expanding the expanding collet 210 in order to perform thepressing and/or folding actions. Rather, the actuation is integral tothe construction of the system 100. As the container 202 and chuck 220are brought together, the container/chuck axial forces may convert toforces applied in the radial direction and/or to specific forces appliedto certain portions of the closure 202. This may advantageously save onpower and/or wear of the expanding collet 210 because when the system100 is utilized without a container 202 in place, the collet 210 willnot expand. In some embodiments, the expanding collet 210 may onlyexpand when a container 202 is pressed against the collet segments 212.

In some embodiments, the action of the expanding collet 210 is resistedby the hoop strength of the container 202. In some embodiments, theactuation and/or action of the expanding collet 210 relative to thechuck 220 may be caused by the upward force of the rim 205 of thecontainer 202 against specific portions (e.g., the lips 215) of theexpanding collet 210. In some embodiments, the resistance of theexpanding collet 210 to this upward force may be tailored to the hoopstrength of the container 202. The hoop strength of the container 202may vary based on the thickness of the sidewall 206, the diameter of thecontainer 202, and/or the height of the container 202, for example.

In some embodiments, the expanding collet 210 may be formed from anon-metal material (e.g., plastic, ceramic, resin). For example, thecollet segments 212 may be formed from nylon (e.g., nylon-12) or acombination of nylon and glass. The collet segments 212 may beindividually formed using a three-dimensional (3D) printer and thenassembled into the expanding collet 210 through engagement with thechuck 220 and/or retainer 211. Forming the expanding collet 210 from anon-metal material may aid in the fusing of the closure 204 to thecontainer 202 in embodiments where induction heating is utilized. Inthis way, the non-metal materials may not be heated due to the inductionheating.

As shown in FIG. 18 , in some embodiments, the assembly module 200 mayinclude a membrane 260 arranged around the expanding collet 210 toprevent ingress of debris between the collet segments 212 as theexpanding collet 210 expands and small gaps are created between thecollet segments 212. For example, the membrane 260 may be formed fromsilicone, rubber, and/or any other expandable material. In someembodiments, the membrane may be a sleeve that is fitted snugly over theexpanding collet 210.

In certain embodiments, the expansion of the expanding collet 210 causessmall gaps to be created between the collet segments 212 and when theindividual collet segments 212 are pressed against the inner sidewall ofthe container, ridges may form in the closure 204, between colletsegments 212. It should be understood that these ridges in the closure204 do not pose an issue from a hermeticity standpoint. The ridge ismerely a compression mark into the actual paper. However, the membrane260 may additionally serve to reduce or eliminate ridge lines fromforming on the closure 204, as the pressure from the individual colletsegments 212 is distributed more uniformly when the membrane 260 is inplace.

Collet Segments

As noted, the expanding collet 210 may comprise multiple pivoting colletsegments 212, the pivoting action of which provides the expansion of theexpanding collet 210. Any number of pivoting collet segments 212 isencompassed within the present disclosure. In some embodiments, theexpanding collet 210 comprises between about twenty and forty pivotingcollet segments 212. In some embodiments, the expanding collet 210comprises at least twenty pivoting collet segments 212. In someembodiments, the expanding collet 210 comprises thirty-two pivotingcollet segments 212. Other amounts of collet segments 212 are possible(e.g., two, four). A greater number of pivoting collet segments 212 mayprovide smaller space or gaps between the segments, a benefit that willbe explained herein.

As shown in FIG. 10 , a portion of each collet segment 212 may beinserted into a segment alcove 222 formed into the circumferentialsurface of the lower portion 220 b of the chuck 220. The segment alcove222 may be configured to be larger than the collet segment 212, therebyallowing the collet segment 212 to move within the segment alcove 222.In some embodiments, each collet segment 212 may have an individualsegment alcove 222 within the chuck 220. For example, the chuck 220 mayinclude thirty-two segment alcoves 222 formed into its lower portion 220b. In some embodiments, the number of segment alcoves 222 formed intothe chuck 220 may be less than the number of collet segments 212 in theexpanding collet 210, such that multiple collet segments 212 share onesegment alcove 222.

Each segment alcove 222 may include radially-oriented sidewallsseparating it from adjacent segment alcoves 222. In this way, thesidewalls of the segment alcoves 222 may form spokes emanating out fromthe central axis of the chuck 220. Having sidewalls for the segmentalcoves 222 may help keep each collet segment 212 from movingcircumferentially relative to the chuck 220 as the chuck 220 rotates. Inthis way, the sidewalls of the segment alcoves 222 may aid in theengagement of the expanding collet 210 with the chuck 220.

In addition to sidewalls, each segment alcove 222 may include a lowerledge or front stop 229 a, an upper ledge or back stop 229 b, and a rearwall 229 d. The rear wall 229 d may be located radially inward towardthe central axis of the chuck 220. The rear wall 229 d may include acurved inlet 229 c in which a curved tip of the collet segment 212engages to for the pivot point 213, around which each collet segment 212pivots.

Each collet segment 212 comprising the generally cylindrical expandingcollet 210 may be generally wedge-shaped with two planar sides 212 a anda peripheral surface 212 b that wraps around the collet segment 212. Thecollet segment 212 may be oriented with respect to the chuck 220 so thatthe planar sides 212 a are parallel or substantially parallel to theradial direction of the chuck 220 (and/or the sidewalls of the segmentalcoves 222) and so that the peripheral surface 212 b is generallyperpendicular to the radial direction of the chuck 220, as shown in FIG.8 .

Each collet segment 212 may have distinct portions around its peripheralsurface 212 b, such as a closure contour surface 212 c, a pivotingportion 214 a (which may be engaged with the segment alcove 222 of thechuck 220, forming a pivot point 213), a front stop portion 214 b(configured to contact a front stop 229 a of the chuck 220 in itsunexpanded state (unexpanded state shown in FIG. 7 ), a back stopportion 214 c (configured to contact a hard back stop 229 b of the chuck220 in its fully expanded state, as shown in FIG. 8 ), and/or a sidestop portion 214 d (configured to contact the side stop 238 of theperipheral sleeve 230 when the roller 250 pushes the peripheral sleeve).

In some embodiments, the collet segments 212 may each include additionalportions or elements within each portion, such as a compression outdent214 e (configured to contact and compress an o-ring (e.g., compressibleback stop 227) before the back stop portion 214 c hits the hard backstop 229 b of the chuck 220) and/or a retainer nook 214 f (configured toreceive retainer 211 therein such that the collet segments 212 areretained in their engagement with the chuck 220).

Closure Contour Surface

Advantageously, the collet segment 212 may be shaped such that certainportions of the peripheral surface 212 b (e.g., closure contour surface212 c) that are configured to contact (e.g., press and/or push) theclosure 204, are shaped in a manner to mimic or mirror the desired finalprofile of the closure 204 on the container 202 when assembled. In thisway, at least a portion of the closure 204 may be formed into the shapedesired for the end-product during fusing when the collet segments 212are fully pivoted and the expanding collet 210 is in its fully expandedstate. For example, the closure contour surface 212 c comprises threesurfaces in an embodiment (e.g., two substantially horizontal surfaces215, 216 b and one substantially vertical surface 216 a therebetween),forming two substantially right angles.

Other profiles of the closure contour surface 212 c are possible, suchas a horizontal surface (horizontal may be useful as the orientation ofthe first surface to ensure stability of the container assembly 406 onceinverted) followed by a longer angled surface that meets with anotherhorizontal surface. As another example, the profile of the closurecontour surface 212 c may include a horizontal surface followed by along arcuate surface, such that the closure forms a dome shape on theunderside of the container assembly 406. In yet another example, theprofile of the closure contour surface 212 c may include a slantedsurface followed by another slanted surface meeting at acute or otherangles in a repeating pattern, such that the underside of the bottom ofthe container assembly 406 forms ridges for sitting better on unevensurfaces. In some embodiments, the surfaces within the profile of theclosure contour surface 212 c may include outward extending ridgesand/or other surface textures desired to be incorporated into the formof the closure on the container assembly 406.

As the closure contour surfaces 212 c of the collet segments 212 form atleast a portion of the desired final profile of the closure 204 in theend-product when the collet segments 212 are fully pivoted and theexpanding collet 210 is in its fully expanded state, it may beadvantageous to minimize the gaps between the fully pivoted colletsegments 212. In order to minimize the gaps, in some embodiments, theexpanding collet 210 may include a greater number of collet segments 212(e.g., at least twenty-four) in order to lessen the gap/interruptedclosure profile between adjacent collet segments 212. In this way,minimizing the space between the collet segments 212 may provide a moreuniform pressing surface against and/or around the sidewall 206 of thecontainer 202. For example, as shown in FIG. 8 , the gap 290 between thethirty-two collet segments 212 may be about 0.025 in. In someembodiments, the gap 290 may range between about 0.01 in. to about 0.25in.

Within the closure contour surface 212 c, each collet segment 212 mayinclude a lip 215 positioned to be engaged by the rim 205 of the openend 203 of the container 202. Alternatively, in some embodiments, suchas where the closure 204 is configured to be assembled completely withinthe open end 203 of the container 202 (e.g., where no portion of theclosure 204 folds over to the rim 205 of the container 202), the lip 215may be located outside of the closure contour surface 212 c, elsewhereon the peripheral surface 212 b.

The lip 215 may be configured to receive the upward force of the rim 205when the container 202 contacts the chuck 220 and collet 210 engagedmechanism. In some embodiments, the lip 215 may be angled slightly suchthat the substantially horizontal surface of the lip 215 angles slightlytoward the central axis of the expanding collet 210. In other words, themore radially-outward end of the substantially horizontal surface of thelip 215 (e.g., the end most distal from the central axis of theexpanding collet 210) is situated lower than the radially-inward end ofthe substantially horizontal surface of the lip 215. In this way, as therim 205 of the container 202 causes the collet segment 212 to pivot, thesubstantially horizontal surface of the lip 215 may be tilted to becloser to 0° horizontal. Having the lip 215 oriented at 0° horizontalmay aid in the application of the upward force of the flat, horizontalrim 205 onto the lip 215 by spreading the force over the larger surfacearea of the entire rim 205. In other words, since both the rim 205 andlip 215 are horizontal and flat, the pressure applied by the upwardforce of the container 202 can be spread across the entire area ofengagement between the rim 205 and lip 215. For example, in embodimentsin which the surface area of the lip 215 is equal to or greater than thesurface area of the rim 205, the upward force may be spread across theentire surface area of the rim 205 where both the lip 215 and rim 205are oriented at 0° horizontal when engaging. Otherwise, the upward forceis more concentrated at the inner or outer corners of the rim 205 if thelip 215 is angled away from 0° horizontal so as to engage more with theinside or outside of the sidewall 206 of the container 202.Additionally, having the lip 215 initially angled slightly such that theouter portion of the lip 215 points slightly downwardly may ensure thatany portions of the closure 204 (e.g., a peripheral skirt 209) extendingbeyond the rim of the container are forced downwardly over and/or aroundthe rim to the exterior wall of the container.

The lips 215 of the collet segments 212 may form the most radiallyoutward portion of the expanding collet 210, such that when the upwardforce of the rim 205 is applied, the distance of each lip 215 from therespective pivot point 213 of the collet segments 212 allows the upwardforce to apply a maximum torque on each collet segment 212. Applying aforce (e.g., constant upward force) against the lip 215 will provide thenecessary torque on the collet segment 212 to cause pivoting at thepivot point 213. In an embodiment, the lip 215 is located distally fromthe pivot point 213. Advantageously, the structural configuration of thecollet segment 212 may optimized for converting the upward force of thecontainer 202 into the pressing forces required for assembling and/orfolding the closure 204 into/around the container 202.

In some embodiments, the length of the substantially horizontal surfaceof the lip 215 of the collet segment 212 may be substantially similar toand/or slightly greater than the thickness of the sidewall 206 of thecontainer 202. The expanding collet 210 may be configured such thatouter circumference of the lips 215 is substantially equivalent to thecircumference of the container 202. In some embodiments, the innerdiameter of the lips 215 may be less than the diameter of the interiorsurface 207 of the container 202, and the outer diameter of the lips 215may be greater than the diameter of the exterior surface 208 of thecontainer 202. Due to the axial alignment of the container 202 with theexpanding collet 210, the engagement and upward force of the rim 205 ofthe container 202 with and on the lips 215 of the expanding collet 210causes the collet segments 212 to all pivot radially outwardsimultaneously.

Adjacent the substantially horizontal surface of the lip 215 toward thecentral axis of the expanding collet 210, each collet segment 212 mayinclude a radially outward-facing substantially vertical surface 216 aas part of the closure contour surface 212 c. The radiallyoutward-facing substantially vertical surface 216 a may be part of anangled tip 216 of the collet segment 212.

In some embodiments, each collet segment 212 may include an angled tip216. The angled tip 216 may be positioned radially inward from andadjacent to the lip 215.

In some embodiments, before the collet segments 212 are pivoted and/orwhen the expanding collet 210 is in its unexpanded state, the radiallyoutward-facing substantially vertical surface 216 a of the angled tip216 may be angled away from the interior surface 207 of the container202 and radially inward toward the center of the expanding collet 210.In other words, the radially outward-facing substantially verticalsurface 216 a of the angled tip 216 may be angled such that the diameterof top portions of the radially outward-facing substantially verticalsurfaces 216 a of the angled tips 216 proximate to the lips 215 isgreater than the diameter of bottom portions of the radiallyoutward-facing substantially vertical surfaces 216 a of the angled tips216 distal from the lips 215. In this way, the combined radiallyoutward-facing substantially vertical surfaces 216 a of all the colletsegments 212 may form a transverse conical section when the expandingcollet 210 is in its unexpanded state.

In some embodiments, the radially outward-facing substantially verticalsurfaces 216 a of the angled tips 216 may be configured to press theinner chuck wall 242 of the closure 204 against the interior surface 207of the container 202 as the collet segments 212 pivot radially outwarddue to the torque applied by the upward force of the rim 205 of thecontainer 202 on the lip 215. As the collet segments 212 are pivoted,the radially outward-facing substantially vertical surfaces 216 a of theangled tips 216 may rotate to become increasingly closer to vertical(e.g., approaching 90°) until the radially outward-facing substantiallyvertical surfaces 216 a become parallel to the interior surface 207 ofthe container 202. In this way, as the collet segments 212 are pivoted,the radially outward-facing substantially vertical surfaces 216 a of theangled tips 216 pivot outward toward the interior surface 207 of thecontainer 202, thereby pushing the inner chuck wall 242 of the closure204 against the interior surface 207 of the container 202, forming acountersink portion 244 (as shown in FIGS. 2B, 2C, and 3 ).

The actuation of the expanding collet 210 may convert the pre-formedchuck wall 242 of the closure 204 into a countersink portion 244 througha pushing, stretching, and/or pressing series of actions.

The length of the radially outward-facing substantially vertical surface216 a of the angled tip 216 may be equivalent to or substantiallyequivalent to the predetermined countersink depth 246 of the countersinkportion 244 of the closure 204 within the open end 203 of the container202 when assembled.

The engagement of the collet segments 212 of the expanding collet 210with the chuck 220 allows the upward force of the container 202 toresult in the inner chuck wall 242 of the closure 204 being pressedagainst the interior surface 207 of the container 202. This pressingaction may aid in creating a seal between the closure 204 and thecontainer 202 during the fusing process.

The collet segments 212 may be configured such that when the diameter ofthe expanding collet 210 is at its maximum diameter in the fullyexpanded state (e.g., as shown in FIG. 8 ), the exterior diameter of theradially outward-facing substantially vertical surfaces 216 a and/orangled tips 216 of the collet segments 212 is substantially equivalentto the inner diameter of the container 202 (e.g., the diameter measuredacross the interior surface 207 of the container 202). For example, theinner diameter of the container 202 and the widest allowable diameter ofthe angled tips 216 may about 2.88 in.

The collet segments 212 may be configured such that when the diameter ofthe expanding collet 210 is at its maximum diameter in the fullyexpanded state (e.g., as shown in FIG. 8 ), the exterior diameter of theradially outward-facing substantially vertical surfaces 216 a and/orangled tips 216 of the collet segments 212 is slightly larger than theinner diameter of the container 202 (e.g., the diameter measured acrossthe interior surface 207 of the container 202). This ensures intimatecontact between the collet segments 212, the container 202, and theclosure 204, in preparation for sealing. In this embodiment, some minorstretching/expansion of the container diameter may occur, within theelastic limits of its comprised materials.

Further radially inward along the closure contour surface 212 c,adjacent the radially outward-facing substantially vertical surface 216a, the angled tip 216 may include a substantially horizontal generallydownward-facing end surface 216 b located at the portion of the angledtip 216 that is farthest vertically from the lip 215. The end surface216 b may be configured to contact the closure 204 and push and/or tampit down into the corner created by the bottom and countersink portion244 of the closure 204.

The combination of the substantially horizontal surface of the lip 215with the radially outward-facing substantially vertical surface 216 aand end surface 216 b of the angled tip 216 may form the closure contoursurface 212 c of a collet segment 212. Advantageously, the closurecontour surface 212 c may substantially outline the desired bottom/endprofile of the end-product or container assembly 406 with the closure204 and container 202 assembled together. When taken all together in theexpanded state of the expanding collet 210, the contoured surfaces(e.g., closure contour surface portion 212 c) of the collet segments 212form the desired shape of the closure 204 inserted into the container202. For example, in some embodiments, the closure contour surface 212 cmay include specific radii of curvature between the various configuredsurfaces that are angled and/or curved as desired. In some embodiments,the desired bottom/end profile of the container assembly 406 may not beuniform along the circumference of the closure 204, and thus, the colletsegments 212 may vary from one another to form specific indents andoutdents (e.g., logos, notches, stabilizing shapes) in the closure 204.

In some embodiments, the angled tip 216 may include an inward-facingsurface 216 c located radially inward from and adjacent to thesubstantially horizontal generally downward-facing end surface 216 b ofthe angled tip 216. In some embodiments, the inward-facing surface 216 cmay be nearly vertical when the expanding collet 210 is in itsunexpanded state, as shown in FIG. 7 . In the fully expanded state ofthe expanding collet 210 (e.g., as shown in FIG. 8 ), the inward-facingsurface 216 c may form nearly a 45° angle with the axial and transverseplanes.

Moving radially inward and axially upward along the collet segment 212,the inward-facing surface 216 c may transition to a retainer nook 214 f.The retainer nook 214 f may be a generally semi-circular cylindricalrecess or downward-facing U-shaped (as viewed in cross-section) portionof the peripheral surface 212 b of the collet segment 212. The retainernook 214 f may be configured such that the retainer 211 (e.g., ano-ring) may be inserted therein.

The expanding collet 210 may, in some embodiments, include a retainer211 engaged with the collet segments 212 within the retainer nook 214 f.For example, the retainer 211 may be an o-ring (e.g., oil-resistantBuna-N o-ring with a 3/16 fractional width, 70A duro, and inner diameterof about 1.6 in.). The retainer 211 may be configured to urge colletsegments 212 to pivot radially inward such that the expanding collet 210is in its unexpanded state with a minimum circumference and/or diameter(e.g., as seen in FIG. 7 ). Thus, without any upward force of acontainer 202 applied to the expanding collet 210 to overcome theresisting force of the retainer 211, the retainer 211 may maintain theexpandable collet 210 in its unexpanded state.

In some embodiments, the retainer 211 may be expandable and comprise amaterial which has elastic or resistive properties, such as rubber. Theresistance of the expandable retainer 211 may be tailored to the hoopstrength and/or upward force of the container 202. The resistance orurging force of the expandable retainer 211 through a predeterminedexpansion may be less than the hoop strength of the container 202.

In some embodiments, the assembly module 200 may be configured such thatthe expandable retainer 211 is expanded by the pivoting action of thecollet segments 212 during a predetermined pivot angle range, thusincreasing the resisting force of the expandable retainer 211. Thecollet segments 212 may be shaped such that the resisting force of theexpanded retainer 211 due to its engagement with the expanding collet210 in the retainer nooks 214 f causes the pressing force of theradially outward-facing substantially vertical surface 216 a on thechuck wall 242 of the closure 204 against the interior surface 207 ofthe open end 203 of the container 202 to be decreased. By decreasing thepressing force of the collet segment 212 and closure 204 against theinterior surface 207 of the container 202 while maintaining the upwardforce of the rim 205 of the container 202 acting on the peripheral skirt209 of the closure 204 and the lips 215 of the collet segments 212, thefull insertion of the closure 204 into the open end 203 of the container202 may be encouraged before allowing the chuck wall 242 of the closure204 to be fully pinched against the interior surface 207 of thecontainer 202.

In some embodiments, the assembly module 200 may be configured such thatthe engagement of the retainer 211 with the expanding collet 210 at theretainer nooks 214 f does not cause the retainer 211 to elasticallyexpand as the collet segments 212 pivot due to the shape of the colletsegments 212 and/or retainer nook 214 f. In such embodiments, theretainer nook 214 f may be eccentrically shaped and/or act as a cam suchthat the retainer 211 maintains the same circumference and/or diameteras the collet segment 212 is pivoted about the pivot point 213. In suchembodiments, the collet segments 212 may be configured to pivot back totheir limit in the unexpanded state at the minimum circumference and/ordiameter of the expanding collet 210 (e.g., as seen in FIG. 7 ) due togravity and/or other timed actuation of the system.

In some embodiments, in the unexpanded state of the expanding collet210, the retainer nook 214 f may be located in line (in the radialdirection) with the front stop 229 a of the chuck 220. A radially inwardwall 214 h of the retainer nook 214 f may extend downward opposite theinward-facing surface 216 c of the angled tip 216 (e.g., as shown inFIG. 10 ). The retainer nook 214 f may include a projecting surface 214g on its radially inward wall 214 h that projects toward theinward-facing surface 216 c of the angled tip 216. The projectingsurface 214 g of the radially inward wall 214 h of the retainer nook 214f may provide resistance such that the retainer 211 will not beunintentionally displaced from within the expanding collet 210. In someembodiments, the projecting surface 214 g of the radially inward wall214 h may comprise a ridge, bump, retention arm, extension, projection,or the like.

Front Stop Portion

Further radially inward from and adjacent to the retainer nook 214 f,the peripheral surface 212 b of the collet segment 212 may include afront stop portion 214 b. The front stop portion 214 b may contact thevertical (or substantially vertical) surface and/or the horizontal (orsubstantially horizontal) surface of the front stop 229 a of the chuck220, when the expanding collet 210 is in its unexpanded state (e.g., asshown in FIG. 7 ). As shown in FIG. 10 , the front stop portion 214 bmay be shaped as a right angle (or a substantially right angle), and thefront stop 229 a may be shaped like a disc (optionally with a squaredtop corner) around the base of the chuck 220 forming the lower ledges ofthe segment alcoves 222.

At rest in the unexpanded state, the collet segments 212 of theexpanding collet 210 may pivot all the way to their limit, which may beprovided by front stop portions 214 b of the collet segments 212contacting the front stops 229 a of the chuck 220 (e.g., the lowerledges of the segment alcoves 222). In the unexpanded state, the colletsegments 212 may be at a minimum pivot angle (e.g., 0°).

In some embodiments, the substantially inward-facing surface of thefront stop portion 214 b may be generally vertical. In some embodiments,the inward-facing surface of the front stop portion 214 b may contactthe vertical (or substantially vertical) surface of the front stop 229 aof the segment alcove 222, when the expanding collet 210 is in itsunexpanded state.

In some embodiments, the substantially downward-facing surface of thefront stop portion 214 b may be generally horizontal. In someembodiments, the downward-facing surface of the front stop portion 214 bmay contact the horizontal (or substantially horizontal) surface of thefront stop 229 a of the segment alcove 222, when the expanding collet210 is in its unexpanded state.

Pivoting Portion

The expanding collet segments 212 may each be configured to pivot abouta pivot point 213 such that the expanding collet 210 changes diameter asthe collet segments 212 pivot between states of expansion. As shown inFIG. 11 , in some embodiments, the pivot point 213 may be centeredwithin the most radially inward portion of the collet segment 212 andmay be adjacent the chuck 220 (e.g., at the rear walls 229 d of thesegment alcoves 222). In this way, the pivot point 213 may be located atthe radially innermost portion of the expanding collet 210, where itengages with the chuck 220 (e.g., at the curved inlet 229 c).

In some embodiments, as shown in FIG. 10 , each collet segment 212 mayhave a curved tip (e.g., pivoting portion 214 a) formed at its mostradially inward portion. In some embodiments, the terminal end of thepivoting portion 214 a may have a circular radius of curvature. In someembodiments, the terminal end of the pivoting portion 214 a may have asemi-circular cylindrical shape. The curved tip (e.g., pivoting portion214 a) may be inserted into a cooperating curved inlet 229 c of thechuck 220 having substantially the same radius of curvature. In thisway, the interface between the curved tip (e.g., pivoting portion 214 a)and cooperating curved inlet 229 c creates a pivot point 213 for eachcollet segment 212.

Back Stop Portion

Further radially outward from and adjacent to the pivoting portion 214a, the collet segment 212 may include a collet back stop portion 214 c.The collet back stop portion 214 c may be configured to abut the chuckback stop 229 b (e.g., upper ledge of the segment alcove 222) of thechuck 220 when the expanding collet 210 is in its fully expanded state(e.g., as shown in FIG. 8 ). As shown in FIG. 13 , the collet back stopportion 214 c comprise a substantially vertical, substantiallyhorizontal, or obtuse angled (nearly a right angle) portion thatcontacts the vertical surface, horizontal surface, and/or corner of thechuck back stop 229 b of the chuck 220 when the collet 212 is expanded.For example, in an embodiment, a corner of the collet back stop portion214 c may contact a corner of the chuck back stop 229 b, in an alignedmanner, to stop any further expansion of the collet 212.

In some embodiments, a substantially inward-facing surface 219 a of theback stop portion 214 c may be nearly vertical (FIG. 10 ). In someembodiments, the inward-facing surface 219 a of the back stop portion214 c may contact the vertical (or substantially vertical) surface orrear wall 229 d of the back stop 229 b of the chuck 220, when theexpanding collet 210 is in its fully expanded state. However, thiscontact is not necessary.

In some embodiments, the substantially upward-facing surface of the backstop portion 214 c may be generally horizontal. In some embodiments, theupward-facing surface of the back stop portion 214 c may at leastpartially contact the horizontal (or substantially horizontal) surface(e.g., upper ledge of the segment alcove 222) of the back stop 229 b ofthe chuck 220, when the expanding collet 210 is in its fully expandedstate.

In the fully expanded state, the collet segments 212 of the expandingcollet 210 may pivot all the way to their limit, which may be providedby back stop portions 214 c of the collet segments 212 contacting theback stops 229 b of the chuck 220 (e.g., the upper ledges of the segmentalcoves 222). In the fully expanded state, the collet segments 212 maybe at a maximum pivot angle (e.g., about 45°).

In this way, the widest allowable diameter of the angled tips 216 (e.g.,the expanding collet 210) may be controlled by the shape of the colletsegments 212 and the engagement of the collet segments 212 of theexpanding collet 210 with the chuck 220. For example, the back stop 229b of the chuck 220 may prevent the collet segment 212 from pivotingfurther after the maximum pivot angle. The chuck 220, and thus the backstop 229 b, may comprise a rigid, non-compressible material.

In some embodiments, between the substantially upward-facing surface 217a of the back stop portion 214 c and the pivoting portion 214 a, theperipheral surface 212 b of the collet segment 212 may include asubstantially vertical surface 219 a as part of the back stop portion214 c. The substantially upward-facing surface 217 a and substantiallyvertical surface 219 a may form nearly a right angle. In someembodiments, the corner 219 b formed between the substantially verticalsurface 219 a and substantially upward-facing surface 219 a of the backstop portion 214 c may be configured to contact the rear wall 229 d ofthe segment alcove 222 of the chuck 220, when the expanding collet 210is in its fully expanded state. This contact may be in addition oralternatively to the substantially inward-facing surface and/orsubstantially upward-facing surface of the back stop portion 214 ccontacting the vertical surface, horizontal surface, and/or corner ofthe back stop 229 b of the chuck 220 when the expanding collet 210 is inits fully expanded state (e.g., when the collet segments 212 have beenpivoted to their maximum pivot angle).

Further radially outward from and adjacent to the substantiallyinward-facing surface of the back stop portion 214 c, the peripheralsurface 212 b of the collet segment 212 may include a substantiallyupward-facing surface. The substantially upward-facing surface may forman approximately right angle with the substantially inward-facingsurface of the back stop portion 214 c. The substantially inward-facingsurface of the back stop portion 214 c and the substantiallyupward-facing surface may together form a compression outdent 214 e.

In some embodiments, the compression outdent 214 e may be configured toabut a compressible back stop 227 in the chuck 220 when the expandingcollet 210 is in its partially expanded state (e.g., as shown in FIG. 12). The assembly module 200 may include a compressible back stop 227positioned between the upper portion 220 a of the chuck 220 and theexpanding collet 210. More particularly, the compressible back stop 227may be disposed or fitted within a back stop recess 227 a. The back stoprecess 227 a may be formed in the underside of a wide, disc-shapedprojection in the upper portion 220 a of the chuck 220. In someembodiments, the back stop recess 227 a may comprise a semi-circularcylindrical recess or downwardly facing U-shape.

In some embodiments, the compressible back stop 227 may have a retentionbead 227 b formed in the radially inward-facing surface 227 c of theback stop recess 227 a. The radially inward-facing surface 227 c mayhave a generally vertical radial cross-section (e.g., circular whenviewed from a transverse cross-section), whereas the retention bead 227b may form a quadrant of a circle when viewed as a radial cross-section(e.g., as shown in FIG. 10 ). The retention bead 227 b may project fromthe radially inward-facing surface 227 c of the back stop recess 227 atoward the radially outward-facing surface 227 d of the back stop recess227 a (e.g., toward the central axis of the chuck 220). Similar to theradially inward-facing surface 227 c, the radially outward-facingsurface 227 d of the back stop recess 227 a may have a generallyvertical radial cross-section (e.g., circular when viewed from atransverse cross-section). The radially outward-facing surface 227 d maybe an extension of the substantially vertical radially outward-facingsurface of the upper ledge or back stop 229 b of the chuck 220. Theretention bead 227 b may be configured to hold the compressible backstop 227 in place within the back stop recess 227 a. In someembodiments, the retention bead 227 b of the back stop recess 227 a maycomprise a ridge, bump, retention arm, extension, projection, or thelike.

When the expanding collet 210 is in its unexpanded state (e.g., as shownin FIG. 7 ), the compressible back stop 227 may be positioned verticallyabove the collective compression outdents 214 e of the expanding collet210, such that there is a space or distance between the compressibleback stop 227 and the collective compression outdents 214 e of theexpanding collet 210. In this unexpanded state, the compressible backstop 227 may be uncompressed.

When the expanding collet 210 is in its partially expanded state (e.g.,as shown in FIG. 12 ), the compressible back stop 227 may be positionedadjacent the collective compression outdents 214 e of the expandingcollet 210. In some embodiments, the compression outdents 214 e of theexpanding collet 210 rotate upwardly through the space or distancebetween the compressible back stop 227 and the collective compressionoutdents 214 e, toward the compressible back stop 227, until contactingthe compressible back stop 227. In this partially expanded state (e.g.,as shown in FIG. 12 ), the compressible back stop 227 may beuncompressed or at least partially compressed.

The compressible back stop 227 may be configured, in some embodiments,to resist the pivoting of the collet segments 212 after they havepivoted for a predetermined pivot angle (or predetermined upwarddistance of the container 202), such that the pressing force of theangled tip 216 on the chuck wall 242 of the closure 204 against theinterior surface 207 of the open end 203 of the container 202 isdecreased when the compression outdents 214 e compress the compressibleback stop 227. By decreasing the pressing force of the closure 204against the interior surface 207 of the container 202 while maintainingthe upward force of the rim 205 of the container 202 against the closure204 and the lips 215 of the collet segments 212, the full insertion ofthe closure 204 into the open end 203 of the container 202 may beencouraged before allowing the inner chuck wall 242 of the closure 204to be fully pinched against the interior surface 207 of the container202.

The pressing force of the closure 204 against the interior surface 207may provide better sealing of the closure 204 to the container 202. Insome embodiments, the compressible back stop 227 may prevent the angledtip 216 of the collet segments 212 from exerting so much pressure on thecontainer interior surface 207 that the interior surface 207 becomesdistorted. In an embodiment, the pressing force of the closure 204against the interior surface 207 may be between about four hundred andabout five hundred pounds of pressure. In a particularly, embodiment,the pressing force may be about four hundred and seventy-five pounds. Inan embodiment, the pressing force of the container 202 into the collet210 or the collet 210 into the rim 205 of the container 202 may be abouttwenty pounds of pressure, which may translate into a pressing force ofthe closure 204 against the interior surface 207 of about four hundredand seventy-five pounds total (e.g., approximately 1000 PSI). In anembodiment, the invention provides a translated pressure of abouttwenty-three to twenty-four times that which is exerted. In anembodiment, each of the collet segments 212 may press against thecontainer 204 with about fourteen to fifteen pounds of pressure.

In some embodiments, the compressible back stop 227 may be an o-ringmade from foam, rubber, silicone, and/or another compressible material.For example, the compressible back stop 227 may be an oil-resistantBuna-N o-ring with a 3/16 fractional width, 70A duro, and inner diameterof about 1.6 in. The resistance or compressibility of the compressibleback stop 227 through a predetermined compression or compressing pivotangle may be tailored to the hoop strength and/or lifting force of thecontainer 202. The resistance of the compressible back stop 227 throughthe predetermined compression or compressing pivot angle may be keptlower than the hoop strength of the container 202, such that the upwardforce of the rim 205 on the lips 215 of the collet segments 212 causesthe collet segments 212 to pivot and compress the compressible back stop227 without damaging the sidewall 206 of the container 202.

As shown in FIGS. 11-13 , as the rim 205 of the container 202 engagesthe lips 215 of the collet segments 212, the upward force of the rim 205may cause the collet segments 212 to pivot the predetermined pivot anglebefore the substantially upward-facing surface of the compressionoutdent 214 e contacts the compressible back stop 227 and then to pivotthe compressing pivot angle while compressing the compressible back stop227 before the back stop portion 214 c contacts the hard back stop 229 bat the predetermined maximum pivot angle.

In some embodiments where the retainer 211 reduces the pressing force ofthe radially outward-facing substantially vertical surface 216 a throughthe predetermined pivot angle range, the assembly module 200 may notinclude a compressible back stop 227 and/or a compression outdent 214 e.Alternatively, the assembly module 200 may have a compression outdent214 e with a different configuration.

While the collet segments 212, the chuck 220, and the compressible backstop 227 have been described with specific reference to the figures, itshould be understood that any shape and/or geometry which willaccomplish the features set forth herein is encompassed by the presentdisclosure.

Side Stop Portion

In some embodiments, as shown in FIG. 10 , the side stop portion 214 dmay include two surfaces angled in different radially-outwarddirections—an upper surface 241 a and a lower surface 241 b. In theunexpanded state of the expanding collet 210 (e.g., with the colletsegments 212 unpivoted and abutting the front stop 229 a of the chuck220), the upper surface 241 a of the side stop portion 214 d may bepositioned to be contacted by the side stop 238 of the peripheral sleeve230. In the fully expanded state of the expanding collet 210 (e.g., withthe collet segments 212 pivoted against the hard back stop 229 b of thechuck 220), the lower surface 241 b of the side stop portion 214 d maybe positioned to be contacted by the side stop 238 of the peripheralsleeve 230.

As shown in FIG. 7 , in some embodiments, the side stop portion 214 dand/or one or both planar sides 212 a of each collet segment 212 mayinclude a nesting lug 218 a and a cooperating nesting depression 218 b.The nesting lugs 218 a and depressions 218 b may aid in assembling theindividual collet segments 212 together in the properorientation/alignment, particularly while the retainer 211 is positionedwithin the retainer nooks 214 f of the collet segments 212 and/or whilethe pivoting portions 214 a of the collet segments 212 are inserted intothe cooperating curved inlets 229 c of the chuck 220. In someembodiments, the nesting lugs 218 a and depressions 218 b may aid in thesubstantially uniform expansion of the expanding collet 210 in case of adefective rim 205 on a container 202—such as one that is uneven, torn,bent or otherwise does not engage all the lips 215 of the expandingcollet 210 simultaneously.

In some embodiments, as shown in FIG. 11 , the assembly module 200 mayinclude an assembly rod 235. In some embodiments, the assembly rod 235may position and initially insert the closure 204 into the container 202as the container 202 is lifted toward the chuck 220 and expanding collet210 (or as the chuck 220 and collet 210 are moved toward the container202). The assembly rod 235 may be cylindrical and may be positionedconcentrically within the hollow central portion of the chuck 220. Theassembly rod 235 may be configured to move axially to ensure properpositioning of the closure 204 relative to the container 202.Specifically, the assembly rod 235 may be configured to push a centralportion 240 of the closure 204 into the open end 203 of the container202 as the container 202 is lifted toward the chuck 220. The assemblyrod 235 may be integral with and/or further include a centering disc236. The centering disc 236 may be generally cylindrical and may bewider than the assembly rod 235. The centering disc 236 may beconfigured to initially contact the central portion 240 of the closure204 as the closure 204 is pushed into the open end 203 of the container202.

In some embodiments, the assembly rod 235 may contain helical screws onits outermost surface which may engage with corresponding helical screwson the interior surface of the chuck 220. Likewise, in some embodiments,the centering disc 236 may comprise helical screws on its innermostsurface which are configured to correspond to helical screws on theouter surface of the assembly rod 235. In some embodiments, thecentering disc 236 may be axially movable separately from the assemblyrod. In other words, the assembly rod 235 may have a maximum extensionlength and the centering disc 236 may extend axially further than theassembly rod's 235 maximum extension length.

In some embodiments, the assembly rod 235 and the centering disc 236 mayaid in removal of the assembly module 200 from the closure 204. That is,after the assembly is complete, the assembly rod 235 and/or centeringdisc 236 may remain in place after the chuck 220 is moved away from thecontainer assembly 406 and/or the container assembly 406 is moved awayfrom the chuck 220. The assembly rod 235 and/or centering disc 236 mayretain the positioning of the closure 204 and then, lastly, release fromthe surface of the closure 204.

Peripheral Sleeve

As shown in FIG. 12 (and various other figures), the assembly module 200may include a peripheral sleeve 230 surrounding the chuck 220 and theexpanding collet 210. The peripheral sleeve 230 may be configured tofold a peripheral skirt 209 of the closure 204 over the rim 205 andaround the exterior surface 208 of the sidewall 206 of the container202. FIGS. 50-51 illustrate an alternate configuration for theperipheral sleeve 230, which operates in the same manner describedherein.

The peripheral sleeve 230 may be generally cylindrical in nature and mayvertically extend from at least the top of the chuck 220 toapproximately the base of the chuck 220 and expanding collet 210. In theembodiment shown in FIGS. 50-51 , the peripheral sleeve 230 may comprisea neck portion 230 a which is narrower in diameter than the body portion230 b. The neck portion 230 a may be integral with and/or disposed abovethe body portion 230 b. A shoulder portion 230 c may connect the neckportion 230 a and the body portion 230 b.

When the expanding collet 210 is in its retracted/resting unexpandedstate (e.g., as shown in in FIGS. 7, 10-11, and 15 ), a brim 237 of theperipheral sleeve 230 may be disposed adjacent radially outward-facingside stop portions 214 d of the collet segments 212. When the expandingcollet 210 is in its partially expanded state (e.g., as shown in FIG. 12), the brim 237 of the peripheral sleeve 230 may be disposed verticallybelow the lips 215 of the collet segments 212. In these embodiments, theperipheral sleeve 230 may not move vertically. Instead, the lips 215 ofthe collet segments 212 are pivoted upward by the rim 205 of thecontainer 202 and change position. In this way, as the peripheral skirt209 of the closure 204 moves upward with the lips 215 of the expandingcollet 210 and the rim 205 of the container 202, the peripheral skirt209 is folded over the rim 205 of the container 202 and pushed orsqueezed between the peripheral sleeve 230 and the exterior surface 208of the sidewall 206 of the container 202.

The inner brim surface 237 a of the peripheral sleeve 230 may bedisposed on the interior side of the brim 237 and configured to contactthe folded peripheral skirt 209 of the closure 204. The inner brimsurface 237 a may include a knurled or gripping surface texture to grabhold of the peripheral skirt 209 of the closure 204 and minimize anyslippage that could be caused by the rotating parts.

In another embodiment, the inner brim surface 237 a need not be knurledor have a gripping texture. In this embodiment, the skirt 209, whenfolded down and forced into a smaller circumference, may tend to buckleand fold/wrinkle as it occupies a smaller area. In still anotherembodiment, a knurled inner brim surface 237 a may force these wrinklesinto a pattern with repeatable frequency and amplitude and may be morelikely to appear intentionally manufactured.

In some embodiments, the peripheral sleeve 230 may be formed from anon-metal material (e.g., plastic, resin). For example, the peripheralsleeve 230 may be formed from nylon (e.g., nylon-12) or a combination ofnylon and glass. Forming the peripheral sleeve 230 from a non-metalmaterial may aid in the fusing of the closure 204 to the container 202in embodiments where induction heating is utilized.

In some embodiments, the inner diameter of the peripheral sleeve 230 maybe larger than the outer diameter of the container 202.

In some embodiments, the assembly module 200 may include one or moreo-rings (e.g., o-ring 232, 234, 238) positioned between the chuck 220and the peripheral sleeve 230. In some embodiments, the o-rings (e.g.,o-ring 232, 234, 238) may be made from foam, rubber, silicone, and/oranother compressible material. For example, each o-ring (e.g., o-ring232, 234, 238) may be an oil-resistant Buna-N o-ring with a 3/16fractional width, 70A duro, and inner diameter of about 1.6 in. In someembodiments (see FIGS. 50-51 ), many of the o-rings may be optional. Forexample, ring 211 may be provided while omitting the other o-rings.

The peripheral sleeve 230 may be movable rotationally and laterallyalong the o-rings 232, 234 relative to the chuck 220. The peripheralsleeve 230 may be configured to remain stationary in the axial directionrelative to the chuck 220. For clarity, while the peripheral sleeve 230may be axially stationary, the peripheral sleeve 230 may continuouslyspin about its axis and/or revolve around the turret center of themachine.

In an embodiment shown in FIGS. 37-38 , the peripheral sleeve 230 maycomprise a plurality of teeth 231 on its inner axial surface. In anembodiment, these teeth 231 may replace one or more o-rings of thesystem. For example, o-ring 232 could be replaced by the teeth 231. Theteeth 231 may extend radially inwardly from the inner surface 233 of thesleeve 230, in an embodiment. In an embodiment, the teeth 231 need notextend the entire vertical distance of the sleeve 230. The teeth 231 maybe positioned at a discrete circumferential location within the innersurface of the sleeve 230. For example, contrary to FIG. 37 , the teeth231 may not extend to the top surface 239 of the sleeve and may bepositioned vertically lower than the top surface 239.

The teeth 231 may be oriented axially inwardly and may be straight,angularly positioned and/or may comprise a non-zero radius of curvature.In an embodiment, the teeth 231 are disposed in a spiral pattern. Aplurality of teeth 231 may be provided. In some embodiments, each of theteeth 231 has the same angle or radius of curvature. In someembodiments, some of the teeth 231 may have different or alternatingangles or radii of curvature.

In an embodiment, the teeth 231 may engage the chuck 220. The teeth 231may extend from the sleeve 230 such that they are in contact with anouter surface 223 of a neck 221 of the chuck 220 (see FIG. 12 ). In thisembodiment, the neck 221 of the chuck 220 may be more narrow than theremainder of (or portions of) the chuck 220. The tips of the teeth 231may contact the neck 221 of the chuck 220 when the sleeve 230 is in aneutral position (FIG. 12 ). This teeth 231/neck 221 contact may keepthe sleeve 230 in the neutral position unless outside forces areapplied. This contact between the teeth 231 and neck 221 may provide thenecessary spacing between the sleeve 230 and the collet segments 212such that the closure 204 and container rim may be insertedtherebetween. Without the teeth 231 (or a similar mechanism, which isalso encompassed herein), the sleeve 230 could inadvertently movelaterally prior to insertion of the container rim and prevent properinsertion of the container rim and closure 204, potentially jamming thesystem. Thus, it is essential that the sleeve 230 is maintained in aneutral position until contact by the roller 250 and is returned to aneutral position after contact with the roller 250 ceases. The teeth 231ensure this positioning.

The teeth 231 may bias the peripheral sleeve 230 to a laterally neutraland/or stationary position (i.e. FIG. 12 ), but the teeth 231 may flexsomewhat to allow the peripheral sleeve 230 to move laterally whenpressure is applied by the roller 250 (i.e. FIG. 14 ). Thus, when theroller 250 presses into the exterior surface of the sleeve 230, at leastthose the teeth 231 adjacent the portion of the sleeve 230 that isreceiving the pressure may flex inwardly and allow the sleeve 230 tomove axially (laterally) inwardly. As the roller 250 and/or sleeve 230rotate, the correspondingly adjacent teeth 231 flex inwardly. Likewise,when tension is released from a circumferential portion of the sleeve230, the circumferentially corresponding teeth 231 may relax to theirneutral position. This process repeats through the rotations.

In an embodiment, the teeth 231 provide a spring-like mechanism. In aparticular embodiment, the teeth 231 may prevent rotational movement ofthe peripheral sleeve 230 in a direction that is opposite that directionwhich is desired. For example, the teeth 231 shown in FIG. 36 may allowthe sleeve 230 to rotate in a counterclockwise direction, but mayprevent rotation in a clockwise direction. Thus, the teeth may flex inone direction but may not flex in the other direction, preventing suchrotation. In other embodiments, the sleeve 230 may rotate in eitherdirection, but the angle/curve of the teeth is directionally related tothe rotation of the sleeve 230. For example, the teeth 231 shown in FIG.36 may be designed for a sleeve 230 which rotates in a counterclockwisedirection even if it does not prevent rotation in a clockwise direction.

As shown in FIGS. 13-14 , the o-ring 234 may be positioned in adownward-facing o-ring recess formed into the downward-facing surfacewithin the peripheral sleeve 230. The upward-facing surface of the upperportion 220 a of the chuck 220 may be positioned under thedownward-facing o-ring recess to hold the o-ring 234 in place. Theo-ring 232 may be positioned in an inward-facing o-ring recess formedinto an inward-facing surface toward the top of and inside theperipheral sleeve 230. The radially outward-facing surface of the neckportion 220 c of the chuck 220 may be positioned adjacent to and insidethe o-ring 232, which may help keep the o-ring 232 inside theinward-facing o-ring recess. The downward-facing and inward-facingo-ring recesses may have a simple U-shaped cross-section with somewhatsquared corners.

As the peripheral sleeve 230 moves laterally relative to the chuck 220,the o-ring 234 may slide along the upward-facing surface of the upperportion 220 a of the chuck 220. In some embodiments, as the peripheralsleeve 230 moves laterally relative to the chuck 220 the o-ring 232 maycontact the radially outward-facing surface of the neck portion 220 c ofthe chuck 220, thereby resisting the lateral motion of the peripheralsleeve 230 and acting as a compressible side stop.

In other embodiments, the one or more o-rings (232, 234, 238) could besubstituted with a lightweight, wavy, spring steel insert in place. Insuch an embodiment, the spring steel insert may be less prone tocompression set and may be better able to re-center the sleeve 230 afterit has been driven eccentrically. Further, in other embodiments, the oneor more o-rings (232, 234, 238) could be substituted with numerous smallsprings, lateral to the axis.

Roller

With further reference to FIGS. 12-14 and 51 , the assembly module 200may include a roller 250 configured to press laterally against theperipheral sleeve 230 and thereby press a portion of the foldedperipheral skirt 209 of the closure 204 against the exterior surface 208of the sidewall 206 of the container 202. Pressing the peripheral skirt209 against the exterior surface 208 of the sidewall 206 may aid in thefusing process discussed in further detail herein.

In some embodiments, as shown in FIGS. 12-14 , the roller 250 may presslaterally against the body portion 230 b of the peripheral sleeve 230.In other embodiments (see FIG. 51 ), the roller 250 may press laterallyinto the neck portion 230 a and/or shoulder portion 230 c of theperipheral sleeve 230. In any case, the pushing and compressing actionof the peripheral sleeve 230 operates similarly.

The roller 250 may be configured to move laterally relative to the chuck220 to push against the peripheral sleeve 230 using a pushing force. Theperipheral sleeve 230 may be configured to shift eccentrically relativeto the expanding collet 210 and/or the chuck 220 when pushed by theroller 250. In this way, as the roller 250 applies its pushing force onthe peripheral sleeve 230, the pushing force causes the peripheralsleeve 230 to shift eccentrically and pinch a portion of the foldedperipheral skirt 209 of the closure 204 between the inner brim surface237 a of the peripheral sleeve 230 and the exterior surface 208 of thecontainer 202.

As shown in FIGS. 12-14 , the radially outward-facing surface of theroller 250 may include one or more roller o-rings. The roller o-ringsmay fit snugly into curved grooves formed around the radiallyoutward-facing surface (e.g., circumference) of the roller 250. In someembodiments, the roller o-rings may be expandable and stretched to fitinto the curved grooves in the outward-facing circumference of theroller 250. In this way, the contracting force of the roller o-rings mayaid in keeping the roller o-rings in place within the grooves. In someembodiments, the roller o-rings made from foam, rubber, silicone, and/oranother compressible material. As the roller 250 moves laterallyrelative to the peripheral sleeve 230 and chuck 220, the roller o-ringsmay be positioned to contact the substantially vertical radiallyoutward-facing surface of the peripheral sleeve 230. The lateral forceof the roller 250 on the peripheral sleeve 230 may cause the rollero-rings to at least partially compress. The at least partiallycompressed roller o-rings may help to provide a controlled pressingaction of the roller 250 on the peripheral sleeve 230, and thereby, theperipheral sleeve 230 against the peripheral skirt 209 of the closure204 and exterior surface 208 of the container 202.

As the roller 250 forces the peripheral sleeve 230 to move laterallywith respect to the chuck 220, the o-ring 232, acting as a compressibleside stop, may resist the pushing force of roller 250 against peripheralsleeve 230. The pushing force of the roller 250 may cause the radiallyinward-facing surface of the inward-facing o-ring recess to compress theo-ring 232 against the radially outward-facing surface of the neckportion 220 c of the chuck 220. In this way, the o-ring 232 may helpminimize any damage to the chuck 220 caused by the peripheral sleeve230. Additionally, the resistance of the o-ring 232 may aid in thecontrolled pressing action of the peripheral sleeve 230 against theperipheral skirt 209 of the closure 204 and exterior surface 208 of thecontainer 202.

Additionally, the roller 250 may be configured to freely rotate. In thisway, as the roller 250 makes contact with the peripheral sleeve 230 thatis rotating substantially in sync with the rotational speed of thecontainer 202, the roller 250 may also rotate to minimize any damagingor slowing frictional forces between the roller 250 and the peripheralsleeve 230.

The expanding collet 210 may be configured to resist the pushing actionof the roller 250 through its engagement with the chuck 220. In anembodiment, the hoop strength of the container may additionally resistthe pushing action of the roller, working to retain its manufactureddiameter. In some embodiments, the assembly module 200 may include aside stop 238 (e.g., a compressible o-ring) positioned between theperipheral sleeve 230 and expanding collet 210 to minimize any damagethat could otherwise be caused by the pushing action of the roller 250shifting the peripheral sleeve 230 against the expanding collet 210,particularly when there is no closure 204 and/or container 202 presentto pivot the collet segments 212 of the expanding collet 210.Alternatively, in some embodiments, the expanding collet 210 may betimed and/or otherwise synchronized with the system such that the colletsegments 212 of the expanding collet 210 automatically shift withoutrequiring the upward force of the container 202.

After assembly, the closure 204 is countersunk vertically downward withrespect to the rim 205 of the container 202, forming a bottom portionand a countersink portion 244. The countersink portion 244 comprises thechuck wall 242 folded and pressed against the interior surface 207 ofthe open end 203 of the container 202. The bottom portion comprises thecentral portion 240 stretched across and inserted into the open end 203of the container 202. The bottom portion and countersink portion 244 mayeach extend below the rim 205 of the container 406 (e.g., as shown inFIG. 3 ). In some embodiments, after assembly, the closure 204 may forman outer wrapped portion comprising the peripheral skirt 209 pressedand/or folded over (and around) the rim 205 of the container 202. Theouter wrapped portion may also comprise the peripheral skirt 209 pressedagainst the exterior surface 208 of the sidewall 206 of the container202.

As depicted, the chuck 220 and expanding collet 210 of the assemblymodule 200 are positioned above the container 202, however, it should benoted that other orientations are possible. For example, the chuck 220and expanding collet 210 may be axially aligned horizontally, and thecontainers 202 are conveyed past in a sideways orientation and movedtoward the chuck 220 from the left and/or right. As another example, thechuck 220 and expanding collet 210 may be mounted at about 45° or otherangle facing down and to the side, while the containers 202 are conveyedto the chuck 220 and expanding collet 210 at a substantially equivalentangle thereby axially aligning each container 202 with the expandingcollet 210 during assembly of a container 202 with a closure 204.

While disclosed in terms of rigid paper-based composite containers andpaper-based end closures, the containers 202 and closures 204 used withthe assembly module 200 may be made from other materials (e.g.,plastics, metals, pulps, resins).

As shown in FIGS. 15-17 , the operation of the assembly module mayinclude the expanding collet initially in its unexpanded state, wherethe collet segments rest on the chuck unpivoted. As the container movesaxially toward the chuck, the rim of the container actuates theexpanding collet, thereby pivoting the collet segments about theirrespective pivot points until the expanding collet reaches its fullyexpanded state, where the structure of the chuck prevents the colletsegments from pivoting any further. In some embodiments, the chuckand/or expanding collet may include a resistance feature (e.g.,compressible back stop 227) that resists the pivoting of the colletsegments at some point before they reach the maximum pivot angle. Theresistance feature may allow the expanding collet to provide acontrolled pressing action of the closure against the interior surfaceof the container, as the container continues to move axially toward thechuck.

In embodiments wherein the closure 204 is a recessed closure (see FIG.2D), the pressure of the expanding collet against the closure 204 andthe interior sidewall 207 of the container 202 is sufficient to seal thesecond deformed surface 204 d of the closure 204 against the interiorsidewall 207 of the container 202. In this embodiment, there is noportion of the closure 204 (i.e. a skirt) that folded over the rim 205of the container. In an embodiment, a benefit of the expanding colletsystem described herein is that it can be utilized with containershaving varied diameters and thicknesses (of the sidewall, that is) andwith closures having varied diameters and thicknesses. The system canclose and seal one set of containers and then may be used later to closeand seal a different set of containers having a different containersidewall thickness, different container diameter, different closurethickness, and/or a different closure diameter. This provides a dynamicsystem that can be utilized for more than one container type. In anembodiment, the expanding collet system can effectively close and seal acontainer and closure having a thicknesses of 0.010 mm, within a ±0.25mm tolerance, which could represent as much as 25% of the totalassembled wall thickness. This is a significant improvement overequipment known in the art which requires significantly less materialthickness variation.

In other embodiments, however, while the container is moving axiallytoward the chuck to actuate it to its fully expanded state, the rim 205of the container 202 forces the peripheral skirt 209 of the closure pastthe brim 237 a of the peripheral sleeve 230, thereby folding theperipheral skirt 209 of the closure around the rim 205 of the containerbetween the inner brim surface of the peripheral sleeve and the exteriorsurface 208 of the container.

In some embodiments, after the expanding collet is in its fully expandedstate (e.g., when the container is fully actuating the expanding colletand no longer moving axially toward the chuck), as the roller moveslaterally toward the chuck, the roller o-rings push against the exteriorof the peripheral sleeve. The lateral pushing force of the roller causesthe peripheral sleeve to shift eccentrically relative to the centralaxis of the chuck, thereby pressing the folded peripheral skirt of theclosure between the inner brim surface of the peripheral sleeve and theexterior surface of the container. The roller may then move laterallyaway from the chuck to return to its initial position, thereby allowingthe peripheral sleeve to re-center itself relative to the central axisof the chuck. In the embodiment wherein the closure 204 is recessedwithin the container body 202 as shown in FIG. 2D, the roller andperipheral sleeve may operate against the outer sidewall 208 of thecontainer without any intervening closure portion (i.e. skirt). Inanother embodiment wherein the closure 204 is recessed within thecontainer body 202 as shown in FIG. 2D, the roller and peripheral sleevemay not be present and/or may not be operated.

After the closure has been fully assembled with the container 202 tobecome the container assembly 406, the container assembly may moveaxially away from the chuck 220. As the container assembly 406 movesaxially away from the chuck 220, the collet segments 212 may rest on theterminal end of container assembly as they pivot back to their positionsin the unexpanded state.

FIGS. 42 and 43 show an alternative embodiment of the roller 250 andperipheral sleeve 230 configuration. In this embodiment, rather than theroller 250 pressing against a sidewall 249 of the peripheral sleeve 230(see FIG. 15 ), instead, the roller 250 presses against a neck portion247 of the peripheral sleeve 230. Thus, in this embodiment, the neckportion 247 of the peripheral sleeve 230 is circumferentially narrowerthan the remainder of the peripheral sleeve 230. The radially inwardpressure that the roller 250 places on the neck 247 of the peripheralsleeve 230 is sufficient to cause the actions described herein.Furthermore, this configuration may provide more space for the fusingmodule, described below. This configuration may allow the fusing moduleto be positioned adjacent the sealing edge of the container (outside thesleeve 230).

Fusing Module

In another embodiment, the system may include a fusing module 300 forfusing the closure 204 (e.g., paper-based end closure) to the container202 (e.g., rigid composite can). In some embodiments, the fusing module300 may be integrated with the assembly module 200, such that theclosure 204 may be fused to the container 202 concurrently with theassemble and press methods. In some embodiments, the fusing module 300may comprise induction coils 302 that are physically integrated into theassembly module 200, such that the closure 204 may be fused to thecontainer 202 using a combination of the assemble and press methods andthe induction coils 302. As noted, the fusing module 300 may employinductive heating techniques to fuse the closure 204 to the container202. In such embodiments, the fusing module 300 may include at least oneinduction coil 302.

In some embodiments, the induction heater may include a coil throughwhich a high-frequency alternating current is passed, thereby creating ahigh-frequency alternating electromagnetic field. The metal layer of theclosure 204 and/or container 202 is exposed to this alternatingelectromagnetic field, which induces eddy currents (also called Foucaultcurrents) within the metal so as to cause Joule heating due to of theresistance of the metal. This heating of the metal layer then causesheat transfer by conduction to anything in contact with the metal,including any heat-sealable material(s) on the closure and/or side wall.

In an embodiment, a composite conductor 304 may be utilized to hone orfocus the inductive energy of the coil(s) 302 toward the container202/closure 204. Shown in FIGS. 42 and 43 , the composite conductor 304may have a curved body which directs and reflects the energy andmagnetic field lines from the coils 302 toward the container 202/closure204. The specific curvature of the composite conductor 304 may be basedon the design of the coils 302. For example, in some embodiments, thecomposite conductor 304 may comprise a half-moon, U-shape, or C-shape.In some embodiments, the composite conductor 304 may have one or moresections that may be continuous or discontinuous. For example, if twocoils 302 are present, two separate composite conductors 304 may beutilized.

The composite conductor 304 may comprise ferrous material suspended in acomposite, which is then baked and hardened into the desired form. Thatbeing said, the composite conductor 304 may comprise any conductor knownin the art. In an embodiment, the composite conductor 304 may be affixedto the induction coils 302. The coils 302, in turn, may be adjacent theperipheral sleeve 230.

In an embodiment, the closure 204 may comprise at least one metal ormetalized layer and at least one heat-sealable layer. In an embodiment,the container sidewall 206 may comprise at least one metal or metalizedlayer and at least one heat-sealable layer. When the metal layer(s) areheated by induction heating, the heat-sealable layer(s) are heated byconduction, which causes the heat-sealable material to be softened ormelted.

In some embodiments, the induction heating of the seam, followed bycooling (which occurs rapidly upon cessation of the electromagneticfield or movement of the container away from the coil), may result intwo areas of thermal fusing between the closure 204 and the sidewall 206of the container 202. There may be an inner seal between the interiorsurface 207 of the sidewall 206 and a portion of the chuck wall 242 thatlies parallel to and intimately contacts the sidewall 206, and there maybe an outer seal between the exterior surface 208 of the sidewall 206and a portion of what was the peripheral skirt 209 of the closure 204prior to assembly. Likewise, in recessed embodiments such as is shown inFIG. 2D, the induction heating system may thermally fuse only the seconddeformed portion 204 d against the inner surface 207 of the container202.

In an embodiment, the induction coils may be disposed in a manner whichoptimizes the sealing function of the system. Examples of such coilarrangements are shown in FIGS. 19-35 . In some embodiments, theinduction coils may comprise single turn coils. In an embodiment, thecoil configuration is a hairpin coil. In some embodiments, as shown inFIG. 45 , the coil may comprise a flattened coil, such as a coil thathas a rectangular cross-section.

In some embodiments, the induction coils apply heat for approximately0.1 to 1.0 seconds. In other embodiments, the induction coils apply heatfor approximately 0.3 to 0.6 seconds.

In some embodiments, the chuck 220 and/or expanding collet 210 of thepresent disclosure are not metallic (e.g., they may comprise a polymericmaterial) to avoid heating/overheating of those elements. In someembodiments, after induction sealing, the container 202 is sealed andready to be discharged from the chamber.

Many modifications and other embodiments of the present disclosure setforth herein will come to mind to one skilled in the art to which thepresent disclosure pertains having the benefit of the teachingspresented in the foregoing descriptions and the associated drawings.Therefore, it is to be understood that the present disclosure is not tobe limited to the specific embodiments disclosed and that modificationsand other embodiments are intended to be included within the scope ofthe appended claims. Although specific terms are employed herein, theyare used in a generic and descriptive sense only and not for purposes oflimitation.

The invention claimed is:
 1. An assembly module for assembling at leastone container body and at least one closure, the assembly modulecomprising: a chuck configured for axial alignment with the containerbody, wherein the container body comprises an open end circumscribed bya rim; an expanding collet engaged with the chuck and including aplurality of collet segments, each collet segment configured tosimultaneously pivot radially outward about a pivot point when engagedwith the closure and container body to press a countersink portion ofthe closure against an interior wall of the container body as the colletsegments pivot radially outward; a peripheral sleeve surrounding thechuck and the expanding collet; and at least one roller configured tomove laterally relative to the chuck and push against the peripheralsleeve.
 2. The assembly module of claim 1, wherein the peripheral sleevehas an inner diameter larger than an outer diameter of the containerbody.
 3. The assembly module of claim 1, wherein the peripheral sleevefurther comprises: an inner brim with a knurled surface.
 4. The assemblymodule of claim 1, wherein the peripheral sleeve is formed from anon-metal material.
 5. The assembly module of claim 1, wherein thecontainer body is configured to be rotated axially relative the at leastone roller.
 6. The assembly module of claim 1, wherein the expandingcollet resists the pushing action of the roller.
 7. The assembly moduleof claim 1, wherein the peripheral sleeve is configured to shifteccentrically relative to the expanding collet and the chuck when pushedby the at least one roller.
 8. The assembly module of claim 1, whereinas the plurality of collet segments pivot radially outward about thepivot point, the diameter of the expanding collet increases.
 9. Theassembly module of claim 8, wherein the diameter increases byapproximately 5% of the total diameter of the collet.
 10. The assemblymodule of claim 1, wherein the container body is paper-based.
 11. Theassembly module of claim 1, wherein the closures are paper-based. 12.The assembly module of claim 1, further comprising: a backstoppositioned to resist the pivoting of the plurality of collet segmentsafter a predetermined pivot distance.
 13. The assembly module of claim1, wherein: the expanding collet further includes an expandable retainerpositioned radially outward of the pivot point of each collet segment,wherein the expandable retainer is configured to urge the plurality ofcollet segments to pivot radially inward.
 14. The assembly module ofclaim 13, wherein the rim of the open end of the container body has ahoop strength greater than the urging force of the expandable retainerthrough a predetermined expansion.
 15. The assembly module of claim 13,wherein the expandable retainer comprises an o-ring.
 16. The assemblymodule of claim 1, wherein the chuck defines a circumferential inletcircumscribing a wall of the chuck; and wherein each of the colletsegments comprising a pivoting portion configured to engage with thecircumferential inlet; and wherein the pivot point of each of the colletsegments is located where the pivoting portion of each collet segmentengages with the circumferential inlet of the chuck.
 17. The assemblymodule of claim 1, wherein the expanding collet is formed from anon-metal material.
 18. The assembly module of claim 1, wherein eachpivoting collet segment of the expanding collet comprises a lippositioned to engage the rim of the open end of the container body andan angled tip positioned radially inward from the lip, wherein asidewall of the angled tip presses the countersink portion of theclosure against the interior wall of the container body.
 19. Theassembly module of claim 18, wherein, when the diameter of the expandingcollet has increased to the maximum diameter of the expanding collet, anexterior diameter of the angled tips of the plurality of collet segmentsis substantially equivalent to an inner diameter of the container body.20. The assembly module of claim 18, wherein the length of the angledtip correlates to a countersink depth of the closure within the open endof the container body when assembled.
 21. The assembly module of claim18, further comprising: a membrane arranged around the lips and theangled tips of the expanding collet to prevent ingress of debris betweenthe collet segments.
 22. The assembly module of claim 21, wherein themembrane is formed from at least one of silicone and rubber.
 23. Theassembly module of claim 18, wherein the lip comprises a substantiallyhorizontal or curved surface configured to contact the container rim.24. The assembly module of claim 18, wherein the angled tip has an endproximate the lip and an end distal the lip and is angled such that whenthe expanding collet is in an unexpanded configuration, the expandingcollet has a diameter at the angled tip proximate end which is greaterthan a diameter at the angled tip distal end.
 25. The assembly module ofclaim 18, additionally comprising an actuator configured to bring thecontainer body and the chuck axially together.
 26. The assembly moduleof claim 25, further comprising: an assembly rod positionedconcentrically within the chuck and the expanding collet and configuredto move axially to push a central portion of the closure into the openend of the container body as the container body and the chuck arebrought axially together.
 27. The assembly module of claim 18, whereinas the container body and the chuck are brought axially together, thecontainer rim engages with the lips of the collet segments and causesthe sidewall of the angled tips of the collet segments to pivot outwardtoward the interior wall of the container body, thereby pushing theclosure into the open end of the container body and pressing thecountersink portion of the closure between the sidewall of the angledtips of the collet segments and the interior wall of the container body.